Package of water absorbent resin powder

ABSTRACT

A method according to the present invention for producing water absorbent resin powder is a method for producing water absorbent resin having a surface cross-linked structure, and includes: a polymerization step in which an unsaturated monomer aqueous solution is polymerized; a drying step in which a hydrogel cross-linked polymer obtained in the polymerization step is dried; a surface treatment step in which the hydrogel cross-linked polymer or a dried hydrogel cross-linked polymer is subjected to a surface treatment; and a sorting step, carried out after the drying step, in which a foreign matter included in a water absorbent resin is color-sorted from the water absorbent resin entirely or partially. As a result, it is possible to obtain a water absorbent resin which has high properties and is less likely to be colored. In this way, there is provided the water absorbent resin powder production method in which the color sorting technique is used to remove foreign matters from the water absorbent resin.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a Continuation of U.S. patent application Ser. No.12/308,803 filed on Dec. 23, 2008, now U.S. Pat. No. 10,301,398, whichApplication is the U.S. 371 National Phase of International PCT PatentApplication No. PCT/JP2007/064622, filed on Jul. 19, 2007, whichapplication claims priority from Japanese Patent Application No.2006-208929 filed on Jul. 31, 2006. The entire contents of theseapplications are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to (i) a production method of waterabsorbent resin powder which method adopts a color sorting technique soas to remove foreign matters contained in a water absorbent resin and(ii) a package of water absorbent resin powder having less foreignmatters and high properties.

BACKGROUND ART

A water absorbent resin is a white resin represented by a cross-linkedpolyacrylic acid polymer, and it is general that a form of the waterabsorbent resin is powder. The water absorbent resin, particularly waterabsorbent resin powder is used as a sanitary material absorbing agentfor a sanitary napkin, a disposable diaper, and the like. Further, thewater absorbent resin is used for wide variety of purposes, e.g., awater retaining agent, a dehydrating agent, and the like in anagriculture/horticulture field, a civil engineering and constructionfield, and a similar field. However, if the water absorbent resin isleft for a long time, this raises such a problem that an external factorsuch as heat and moisture causes the water absorbent resin to be coloredyellow or brown. Particularly in the sanitary material field, when thewater absorbent resin (powder) of a water absorbing article such as adisposable diaper, a sanitary napkin, and the like is colored, thecolored water absorbent resin in a white pulp causes a consumer toregard the resin as having foreign substances, which significantly dropsits commercial value as the water absorbing article. Thus, the waterabsorbent resin is required to be white not only at the time of shipmentbut also on a permanent basis.

Therefore, there have been proposed several methods each of whichprevents the water absorbent resin from being colored even in case wherethe water absorbent resin is reserved for an extended period of time athigh temperature and high humidity. Examples of the methods include: amethod in which an inorganic reducer and metal salt are added to thewater absorbent resin (Patent Document 1); a method in which sulfinicacid is added as a reducer at the time of polymerization (PatentDocument 2); a method in which an aminocarboxylate metal chelating agentand an oxidizing agent or a reducer are added (Patent Document 3); amethod in which hydroquinones, i.e., impurities of acrylic acid used inpolymerization are controlled (Patent Document 4); a method in whichmethoxyphenols, i.e., inhibitor of acrylic acid used in polymerizationare controlled (Patent Document 5); and the like.

Further, it is natural that the commercial value of the water absorbentresin is decreased by the aforementioned coloring. Also, it is knownthat: if a metallic foreign substance is slightly included in the waterabsorbent resin, this causes deterioration of water absorbingperformance, so that the commercial value of the water absorbent resindecreases. In order to remove the metallic foreign substance slightlyincluded in the water absorbent resin, a method in which a magnetic lineis emitted to the water absorbent resin (specifically, a method using aniron remover) is proposed as a particularly effective method (PatentDocument 6). Further, there is proposed a property stabilization methodin which a product whose property is below or above a certain propertyis sorted and the sorted product is mixed with an original product so asto stabilize a property such as an absorbency under load (PatentDocument 7).

Further, also a method in which a rotary sorting apparatus is used toremove agglomerates each of which has a large particle diameter (PatentDocument 8) is proposed.

[Patent Document 1]

U.S. Pat. No. 6,359,049

[Patent Document 2]

WO2004/084962 (corresponding U.S. Patent Publication No. 2006-089611)

[Patent Document 3]

European Patent No. 1466928 (corresponding U.S. Patent Publication No.2005-085604)

[Patent Document 4]

U.S. Pat. No. 6,444,744

[Patent Document 5]

U.S. Patent Publication No. 2004-0110914

[Patent Document 6]

U.S. Pat. No. 6,716,894

[Patent Document 7]

U.S. Patent Publication No. 2004-0110006

[Patent Document 8]

U.S. Patent Publication No. 2007-041796

DISCLOSURE OF INVENTION

Each of the techniques described in Patent Documents 1 to 5 focuses on acolor of entire particles of water absorbent resin and is to reducebrowning and yellowing of the entire particles. In this technique,numerical values are used as color indexes (YI value, Lab value) of theentire particles. On the other hand, in view of an influence thecoloring of the water absorbent resin has on the human visual sense,black or yellow foreign matters slightly included in the particles haverecently attracted more attentions than the browning or the yellowing ofthe entire particles have, so that it was found that the foreign matters(existence of several color particles) have grater influence.

That is, if the foreign matters are not removed and remain in theproduct, the foreign matters do not influence the safety of the productbut the human visual sense intensely percepts particles of the foreignmatters dotted in white water absorbent resin powder though the entireparticles have the same color indexes (YI value, Lab value), so that theappearance of the foreign matters causes the human visual sense to feelthat the whiteness of the water absorbent resin is insufficient. Such awater absorbent resin causes the consumer to feel the foreign substancesparticularly in use for a diaper or the like which uses a highlyconcentrated water absorbent resin, so that this may result incomplaints from consumers. Thus, the product cannot be shipped and arescrapped as “out of speck”, which results in lower yields and highercosts.

However, each of the techniques described in Patent Documents 1 to 5 isnot to remove the foreign matters which may be slightly included, sothat the resultant water absorbent resin has the uncomfortableappearance caused by the foreign matters. This raises such a problemthat the resultant water absorbent resin is not satisfactory in view ofthe whiteness. That is, conventional arts are not to directed to anyproblem or any finding regarding higher whiteness realized by removingthe foreign matters so that the water absorbent resin is free from anyuncomfortable appearance.

Further, the technique of Patent Document 6 was used for removal of themetallic foreign substances by the inventors of the present invention,but they found it impossible to remove the foreign matters even thoughthe technique of Patent Document 6 is repeatedly used. Further, theforeign substances removed by the technique of Patent Document 6 aremetallic foreign substances derived from a manufactory, so that themetallic foreign substances have no visually uncomfortable appearance asstainless. Furthermore, each of the techniques described in PatentDocuments 7 and 8 exhibits substantially no effect in reduction ofcoloring and reduction of color foreign substances.

As other means for removing the foreign matters, not only such operationthat the foreign matters are regularly monitored so as to be removed,but also the following operations can be adopted: i.e., improvement of apiston flow of a water absorbent resin production apparatus; frequentcleaning carried out at the time of stoppage of a production line;prevention of agglomeration at the time of surface cross-linking so thatadhesion of agglomerates onto an internal portion of the productionapparatus is prevented; prevention of dew condensation in the productionapparatus (prevention of moisture evaporation from the water absorbentresin being heated); and the like. However, each of the operations isextremely troublesome, which results in less efficient production. Thatis, there is such a conventional problem that the conventional art isless efficient and takes higher cost in producing and shipping a waterabsorbent resin having substantially no foreign matters.

It was found that: an amount (the number of particles) of the foreignmatters is generally so small as zero (not more than the detectionlimit) or so small as to be unnoticeable, but continuous productioncarried out for an extended period of time causes the amount toincrease, particularly at the time of production trouble, a greateramount of the foreign matters temporarily occurs. Thus, there is notknown a method for removal of the foreign matters from the waterabsorbent resin which removal has not been cared about.

The present invention was made in view of the foregoing problems, and anobject of the present invention is to provide (i) a water absorbentresin powder production method in which a color sorting technique isused to remove the foreign matters and (ii) a package of water absorbentresin powder which has less foreign matters and has high properties.

The inventors of the present invention diligently studied in view of theforegoing problems. As a result, they found that there are foreignmatters which cannot be removed by repeating the technique described inPatent Document 4, and cut off and analyzed the foreign matters. As aresult, they found that the foreign matters are burned portions of thewater absorbent resin. They found that the foreign matters which areorganic substances cannot be removed by the technique (iron removerusing a magnetic line) described in Patent Document 4. Further,according to the analysis, the foreign matters were free from anyproblem in view of the property and the safety but a large amount of theforeign matters was found in a water absorbent resin whose propertiesare controlled in accordance with various parameters (hereinafter, thewater absorbent resin are referred to as “high property water absorbentresin”). Particularly in a high property water absorbent resin producedby carrying out a surface cross-linking treatment at a high temperatureand continuously carrying out the steps, a large amount of the foreignmatters was found.

While, a smaller amount of the foreign matters was found in a waterabsorbent resin subjected to a low-temperature surface treatment, awater absorbent resin whose surface has not been treated, and a waterabsorbent resin obtained by reverse phase suspension polymerization.Further, a large amount of the foreign matters was found in continuousproduction, in switching products, in changing a production condition,and in restarting the production.

The high property water absorbent resin has a high commercial value dueto its high water absorbing performance, so that it is so necessary toreduce an influence the foreign matters have on appearance of theproduct in preventing the commercial value from decreasing. However, theproduction cost of the high property water absorbent resin is likely toincrease, so that the conventional technique for producing and shippingthe water absorbent resin having substantially no foreign mattersresults in higher cost and less efficient production.

As a result of further study, the inventors of the present inventionfound it possible to efficiently remove the foreign matters by adoptingthe color sorting technique in the production steps after the dryingstep, thereby completing the present invention.

That is, a method according to the present invention for producing waterabsorbent resin powder whose mass average particle diameter defined bysieve classification is 300 μm or more and 10 mm or less and whichcontains less than 10% by mass of fine powder having a particle diameterof 150 μm or less and has a surface cross-linked structure, said methodbeing characterized by comprising: a polymerization step in which anunsaturated monomer aqueous solution is polymerized; a drying step inwhich a hydrogel cross-linked polymer obtained in the polymerizationstep is dried; a surface treatment step in which the hydrogelcross-linked polymer or a dried hydrogel cross-linked polymer issubjected to a surface treatment; and a sorting step, carried out afterthe drying step, in which a foreign matter included in a water absorbentresin is color-sorted from the water absorbent resin entirely orpartially.

According to the arrangement, as to the high property water absorbentresin in which foreign matters are likely to occur, a color of afavorable water absorbent resin is regarded as a background color, and acolor of the foreign matters is compared with the background color,thereby removing the foreign matters. Thus, it is not necessary to carryout a troublesome operation for removing foreign matters, e.g., it isnot necessary to carry out an operation in which a production line isstopped and cleaned, so that it is possible to more efficiently producethe water absorbent resin powder. Also, it is possible to stably andefficiently obtain, in a continuous manner, a water absorbent resinwhose appearance is free from any uncomfortable appearance and which hashigh properties, excellent whiteness, and is less likely to be colored,for an extended period of time.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that an air jetis emitted so as to color-sort the foreign matter. According to thearrangement, an air jet is emitted to particles determined as foreignmatters as a result of the color sorting. Thus, it is possible toefficiently remove from the production line or after the production in apinpoint manner.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that a digitalimage process is carried out so as to color-sort the foreign matter.According to the arrangement, it is possible to narrow an area detectedby the sensor, so that it is possible to more exclusively detect theforeign matters. Thus, it is possible to decrease a ratio of favorableparts removed together with the foreign matters.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that the dryingstep and the surface treatment step are carried out by heating thehydrogel cross-linked polymer or the dried hydrogel cross-linked polymerat 150° C. or higher and 250° C. or lower. According to the arrangement,the drying and the surface cross-linking are carried out at hightemperature, so that the surface cross-linking is firmly carried out,thereby obtaining a water absorbent resin having higher water absorbingperformance and extremely high properties. Thus, it is possible toenhance the whiteness of the water absorbent resin, having extremelyhigh properties, which is subjected to the color sorting.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so as to furthercomprise a continuous transport step, carried out after the drying step,which links a pulverization step, a classification step, and productionsteps, wherein production is continuously carried out for 30 days ormore and 1000 days or less. It was found that the foreign matters areburned portions of the water absorbent resin and this results from suchcondition that the water absorbent resin remains in the production lineand is burned. Thus, a large amount of the foreign matters is found inthe production line having continuous steps, i.e., the production lineincluding, after the drying step, a pulverization step, a classificationstep, and a continuous transport step which links respective productionsteps.

Further, a large amount of the foreign matters is found in carrying outcontinuous production, switching a product, changing a productioncondition, and restarting the operation. Thus, according to thearrangement, the color sorting is carried out in the production lineincluding the continuous steps, so that it is possible to efficientlyremove the foreign matters without stopping the continuous steps for apurpose of cleaning and the like, thereby greatly reducing the cost andproducing the water absorbent resin powder more efficiently.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that 20 Kg to200000 Kg of the water absorbent resin is packaged into eachnon-permeable bag or each non-permeable container and the sorting stepis carried out right before or right after packaging a final product. Asdescribed above, a large amount of the foreign matters is found in thesurface cross-linked product, so that it is possible to efficientlyremove the foreign matters by carrying out the sorting step right beforeor right after packaging a final product.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that the waterabsorbent resin subjected to the color sorting is water absorbent resinpowder obtained by carrying out cross-linking polymerization withrespect an unsaturated monomer containing acrylic acid and/or saltthereof as a main component, and the water absorbent resin satisfies thefollowing properties:

(a) an absorbency against pressure (AAP: 0.90 g) is 20 g/g or more and60 g/g or less;

(b) an amount of fine powder whose particle diameter is 150 μm or lessis 0 mass % or more and 5 mass % or less, and a mass average particlediameter (D50) is 300 μm or more and 600 μm or less, and a particle sizedistribution logarithmic standard deviation (σζ) is 0.20 or more and0.40 or less, defined by standard sieve classification, where theabsorbency against pressure (AAP: 0.90 g) represents an absorbency of0.9 g of a particulate water absorbing agent for 0.90 mass % sodiumchloride aqueous solution under a pressure of 4.8 kPa for 60 minutes.

According to the arrangement, the absorbency against pressure (AAP: 0.90g) is extremely high, so that the resultant water absorbent resin powderstably exhibits high properties regardless of an amount of the waterabsorbent resin (concentration) in a diaper, and its permeability ishigh. Further, its particle size is adjusted to a specific particle size(b), so that properties in surface cross-linking is improved.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that the colorsorting is repeated plural times. It is possible to improve the yield bysorting particularly a water absorbent resin having been sorted andcontaining the sorted foreign matters.

It is preferable to arrange the method according to the presentinvention for producing water absorbent resin powder so that aqueoussolution polymerization, particularly, continuous aqueous solutionpolymerization, further continuous belt polymerization or continuouskneader polymerization is carried out as the polymerization. Accordingto the arrangement, it is possible to highly productively obtain a waterabsorbent resin having high properties.

A package according to the present invention for packaging waterabsorbent resin powder obtained by carrying out cross-linkingpolymerization with respect to an unsaturated monomer containing acrylicacid and/or salt thereof as a main component, said package comprising anon-permeable bag or a non-permeable container containing 20 kg to200000 kg of the water absorbent resin powder as each package, aproduction volume of the package being 100 Mton or more, said waterabsorbent resin powder satisfying the following properties:

(a) an amount of a foreign matter included in the water absorbent resinpowder is 5 mm²/100 g or less;

(b) an absorbency against pressure (AAP: 0.90 g) is 20 g/g or more and60 g/g or less;

(b) an amount of fine powder whose particle diameter is 150 μm or lessis 0 mass % or more and 5 mass % or less, and a mass average particlediameter (D50) is 200 μm or more and 550 μm or less, and a particle sizedistribution logarithmic standard deviation (σζ) is 0.20 or more and0.40 or less, defined by standard sieve classification, where theabsorbency against pressure (AAP: 0.90 g) represents an absorbency of0.9 g of a particulate water absorbing agent for 0.90 mass % sodiumchloride aqueous solution under a pressure of 4.8 kPa for 60 minutes.

According to the arrangement, it is possible to provide a waterabsorbent resin which is suitable for mass consumption and has lessforeign matters, and it is possible to exhibit high properties in adiaper and it is possible to prevent any uncomfortable appearancederived from the foreign matters.

Further, the resultant water absorbent resin powder has an extremelysmall amount of foreign matters as indicated by the property (a). Thatis, a small amount of black or brown particles is contained, so that thewhiteness is extremely high. Thus, it is possible to provide a highquality particulate water absorbing agent which is excellent in bothappearance and performance. Further, according to the arrangement, it ispossible to continuously produce the high property water absorbent resinwithout raising the problem of the foreign matters, and it is possibleto produce a water absorbent resin which is favorable in view of (i)balance with properties and (ii) cost performance.

For a fuller understanding of the nature and advantages of theinvention, reference should be made to the ensuing detailed descriptiontaken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 is a diagram schematically illustrating an arrangement of a colorsorting apparatus 1 used as an example of the present embodiment.

REFERENCE NUMERALS

-   -   1 Color sorting apparatus    -   11 Feeder    -   12 Chute    -   13 Sorting room    -   14 Sensor    -   15 Lamp    -   16 Reflector    -   17 Air gun    -   18 Nondefective product collecting cylinder    -   19 Defective product collecting cylinder    -   100 Water absorbent resin

BEST MODE FOR CARRYING OUT THE INVENTION

One embodiment of the present invention is described below. However, thepresent invention is not limited to this.

(1. Water Absorbent Resin Powder Production Method)

In one embodiment, a method according to the present invention forproducing water absorbent resin powder having a surface cross-linkedstructure includes: a polymerization step; a drying step; a surfacetreatment step; and a sorting step, serving as a production step carriedout after the drying step, in which foreign matters contained in a waterabsorbent resin are subjected to color sorting. A particle size of thewater absorbent resin before or after the color sorting is preferablysuch that a mass average particle diameter is 300 μm or more and 10 mmor less and an amount of fine powder whose particle diameter is 150 μmor less is less than 10 mass %.

Note that, the water absorbent resin of the present invention generallyrefers to a water-insoluble and water-swelling polymer gelatinizingagent whose centrifugal retention capacity (CRC) is 10 g/g or more andwhich contains 50% or less of a water-soluble polymer as a water-solublecomponent. Further, the water absorbent resin powder of the presentinvention refers to powder obtained by pulverizing, as necessary, adried hydrogel cross-linked polymer (water absorbent resin) into apowdery form. The water absorbent resin powder produced by the methodaccording to the present invention for producing water absorbent resinpowder is such that its average weight particle diameter is 300 μm ormore and 10 mm or less and an amount of fine powder whose particlediameter is 150 μm or less is less than 10 mass %.

<Polymerization Step>

First, the polymerization step is described as follows. Thepolymerization step is a step of polymerizing aqueous solution of anunsaturated monomer so as to generate a hydrogel cross-linked polymer.

As the polymerization of the present invention, it is preferable tocarry out reverse phase suspension polymerization or aqueous solutionpolymerization, particularly continuous aqueous solution polymerizationsuch as aqueous solution polymerization, continuous belt polymerization,and continuous kneader polymerization, in view of properties and in viewof prevention of occurrence of foreign matters. Note that, the reversephase polymerization is a polymerization method in which a monomeraqueous solution is suspended in a hydrophobic organic solvent. Forexample, the polymerization method is described in U.S. Pat. Nos.4,093,776, 4,367,323, 4,446,261, 4,683,274, 5,180,798, 5,244,735, andthe like.

The aqueous solution polymerization is a method in which a monomeraqueous solution is polymerized without using any dispersion solvent.For example, the polymerization method is described in U.S. Pat. Nos.4,625,001, 4,873,299, 4,286,082, 4,973,632, 4,985,518, 5,124,416,5,250,640, 5,264,495, 5,145,906, 5,380,808, 6,174,978, 6,241,928,6,987,151, 6,710,141, 6,867,269, 6,906,159, 7,091,253, U.S. PatentPublication No. 2005-0215734, U.S. Patent Publication No. 2006-0167198,and the like, European Patent No. 0811636, European Patent No. 0955086,European Patent No. 0922717, and the like. A monomer, a cross-linkingagent, a polymerization initiator, and other additive that are describedin these documents are applicable to the present invention.

According to the aqueous solution polymerization, the continuous beltpolymerization (U.S. Pat. No. 4,857,610, U.S. Patent Publication No.2005-0215734 and U.S. Patent Publication No. 2006-0167198 for example),and the continuous kneader polymerization (U.S. Pat. Nos. 6,987,151 and6,710,141 for example), it is not necessary to add any organic solvent,so that each of these polymerization methods has less influence on theenvironment than the reverse phase suspension polymerization and isexcellent in safety, and it is possible to carry out the polymerizationand the drying at a high temperature. Thus, productivity and propertythereof are excellent, but foreign matters derived from a hightemperature are likely to occur. Thus, the present invention can befavorably applied.

The unsaturated monomer is a water-soluble monomer. Specific examplesthereof includes: acid group monomers such as (meth)acrylic acid,β-acryloyl oxypropionic acid, maleic acid, maleic anhydride, fumaricacid, crotonic acid, itaconic acid, cinnamic acid,2-(meth)acryloylethane sulfonic acid, 2-(meth)acryloylpropane sulfonicacid, 2-(meth)acrylamide-2-methylpropane sulfonic acid, vinyl sulfonicacid, stylene sulfonic acid, allyl sulfonic acid, vinyl phosphonic acid,2-(meth)acryloyloxyethyl phosphoric acid, and (meth)acryloxyalkanesulfonic acid; alkali metal salt and alkali earth metal salt thereof,ammonium salt, and alkylamine salt; dialkylamino alkyl (meth)acrylatessuch as N,N-dimethylaminoethyl (meth)acrylate, N,N-dimethylaminopropyl(meth)acrylate, and N,N-dimethylaminopropyl (meth)acrylamide, andquaternaries thereof (e.g., a reactant obtained by reaction withalkylhalide, a reactant obtained by reaction with dialkylsulfate, andthe like); dialkylaminohydroxyalkyl (meth)acrylates and quaternariesthereof; N-alkylvinylpyridinium halide; hydroxymethyl (meth)acrylatesuch as hydroxymethyl (meth)acrylate, 2-hydroxyethyl methacrylate, and2-hydroxypropyl (meth)acrylate; acrylamide, methacrylamide, N-ethyl(meth)acrylamide, N-n-propyl (meth)acrylamide, N-isopropyl(meth)acrylamide, and N,N-dimethyl (meth)acrylamide;alkoxypolyethyleneglycol (meth)acrylate such asmethoxypolyethyleneglycol (meth)acrylate, polyethyleneglycolmono(meth)acrylate; vinylpyridine, N-vinylpyridine, N-vinylpyrrolidone,N-acryloylpiperidine; N-vinylacetamide; and the like. These unsaturatedmonomers may be used independently or in a suitable combination of twoor more kinds.

Among the above-exemplified water-soluble unsaturated monomers(excluding the cross-linking agent), it is preferable to use a monomercontaining as a main component the acrylate monomer (50 mol % or more,preferably 70 to 100 mol %, more preferably 90 to 100 mol % with respectto the entire monomer) since the water absorbing performance and thesafety of the resultant hydrogel. Note that, the “water-soluble” means astate in which 1 g or more, preferably 10 g or more of a monomerdissolves in 100 g of water at a room temperature (normal temperatureand normal pressure).

Herein, the acrylate salt monomer refers to acrylic acid and/or acrylicacid water-soluble salts. Further, the acrylic acid water-soluble saltsare acrylic acid alkali metal salt, acrylic acid alkali earth metalsalt, acrylic acid ammonium salt, acrylic acid hydroxy ammonium salt,acrylic acid amine salt, and acrylic acid alkylamine salt, whoseneutralization rate is 30 mol % or more and 10 mol % or less, preferably50 mol % or more and 99 mol % or less.

Among the above-exemplified water-soluble salts, monovalent salt,particularly preferably, sodium salt and potassium salt. These acrylatesalt monomers may be used independently or in a suitable combination oftwo or more kinds. Note that, an average molecular weight(polymerization degree) of the water absorbent resin is not particularlylimited.

In the polymerization step, a monomer composition containing theunsaturated monomer as a main component is polymerized preferably in thepresence of a minute amount of the cross-linking agent, therebyobtaining the aforementioned hydrogel cross-linked polymer. The hydrogelcross-linked polymer may be a self-cross-linking type obtained withoutusing the cross-linking agent, but it is preferable to copolymerize orreact a cross-linking agent having two or more polymerizable unsaturatedgroups in its molecule or two or more reaction groups in its molecule.

Further, the monomer composition may include other hydrophobicunsaturated monomer which is copolymerizable with the aforementionedunsaturated monomer as long as hydrophilicity of the resultant hydrogelcross-linked polymer is not inhibited. Specific examples of thecopolymerizable monomer include: (meth)acrylic acid esters such asmethyl (meth)acrylate, ethyl (meth)acrylate, and butyl (meth)acrylate; ahydrophobic monomer, having no acid group, no hydroxyl group, and noamino group, e.g., vinyl acetate and vinyl propionate; and the like.These copolymerizable monomers may be used independently or in asuitable combination of two or more kinds.

Further, examples of the cross-linking agent (referred to also as“internal cross-linking agent) include: a compound having a plurality ofvinyl groups in its molecule; a compound having a plurality offunctional groups, reactable with a carboxyl group and a sulfonic acidgroup, in its molecule; a compound having a vinyl group and a functionalgroup, reactable with a carboxyl group and a sulfonic acid group, in itsmolecule; and the like. These cross-linking agents may be used inindependently or in a suitable combination of two or more kinds. It ispreferable to use at least a compound having a plurality of vinyl groupsin its molecule.

Specific examples of the compound having a plurality of vinyl groups inits molecule include: N,N′-methylenebis(meth)acrylamide,(poly)ethyleneglycol di(meth)acrylate, (poly)propyleneglycoldi(meth)acrylate, (ethyleneoxide denatured)trimethylolpropanetri(meth)acrylate, trimethylolpropanedi(meth)acrylate,glycerinetri(meth)acrylate, (ethyleneoxide denatured)glycerineacrylatemethacrylate, pentaerythritoltetra(meth)acrylate,dipentaerythritolhexa(meth)acrylate, N, N-diallylacrylamide, triallylcyanurate, triallyl isocyanurate, triallyl phosphate, triallyl amine,diallyloxy acetate, bis(N-vinylcarboxilate amide), (ethyleneoxidedenatured) tetraallyloxiethane, and the like.

Further, as the compound having a plurality of functional groupsreactive with a carboxyl group and a sulfonic acid group in itsmolecule, it is possible to use below-exemplified surface cross-linkingagents (polyhydric alcohol, polyhydric glycidyl compound, polyhydricamine compound, alkylenecarbonate compound, polyhydric metal salt, andthe like) as an internal cross-linking agent at the time ofpolymerization.

An amount of the cross-linking agent to be used is not particularlylimited, but the amount is preferably 0.0001 mol % or more and 10 mol %or less, more preferably 0.001 mol % or more and 1 mol % or less, stillmore preferably 0.01 mol % or more and 0.5 mol % or less, with respectto the aforementioned monomer components. In the present invention, amethod for polymerizing the monomer components is not particularlylimited, but examples thereof include: aqueous solution polymerization;still polymerization carried out on a tray or a belt; polymerizationcarried out in a kneader; and the like.

Further, in carrying out the aqueous solution polymerization withrespect to the unsaturated monomer, either continuous polymerization orbatch polymerization may be adopted. Also, the polymerization may becarried out at any one of a normal pressure, a reduced pressure, and anincreased pressure. Note that, it is preferable to carry out thepolymerization reaction in an air current of inert gas such as nitrogen,helium, argon, and carbon dioxide.

In initiating the polymerization of the polymerization reaction, it ispossible to use a polymerization initiator or an activation energy raysuch as a radiation ray, an electron ray, an ultraviolet ray, and anelectromagnetic ray. The polymerization initiator is not particularlylimited, but it is possible to use a thermal decomposition initiator ora photodecomposition initiator. Examples of the thermal decompositioninitiator include: persulfate such as sodium persulfate, potassiumpersulfate, and ammonium persulfate; peroxide such as hydrogen peroxide,t-butylperoxide, and methylethylketoneperoxide; azo compound such asazonitryl compound, azoamidine compound, cyclic azoamidine compound,azoamide compound, alkylazo compound,2,2′-azobis(2-amidinopropane)dihydrochloride, and2,2′-azobis[2-(2-imidazoline-2-yl) propane] dihydrochloride]. Examplesof the photodecomposition initiator include: benzoin derivative, benzylderivative, acetophenone derivative, benzophenone derivative, and azocompound. These polymerization initiators may be used independently orin a suitable combination thereof. Further, in case of using peroxide asthe polymerization initiator, for example, a reducer such as sulfitesalt, bisulfite, and L-ascorbic acid may be used together so as to carryout oxidation reduction (redox) polymerization.

An amount of the polymerization initiator to be used is not particularlylimited, but the amount preferably ranges from 0.0001 to 1 mol %, morepreferably from 0.01 to 0.5 mol %, still more preferably from 0.03 to0.3 mol % with respect to the monomer components in view of the propertyand the productivity.

In polymerizing the monomer components in the presence of thecross-linking agent, it is preferable to use water as solvent. That is,it is preferable to use the monomer components and the cross-linkingagent in a form of aqueous solution. This improves the water absorbingperformance of the resultant water absorbent resin.

A concentration of the monomer components in the aqueous solution(hereinafter, referred to as “monomer aqueous solution”) is preferably20 wt % or more and 75 wt % or less, more preferably 25 wt % or more and65 wt % or less. In case where the concentration of the monomercomponents is less than 20 wt %, a water extractable polymer content ofthe resultant water absorbent resin may increase. Also, in this case,foam is not sufficiently generated by a foaming agent and polymerizationheat (boiling caused by the polymerization heat), so that it may beimpossible to improve an absorption rate. While, in case where theconcentration of the monomer components exceeds 75 wt %, it may bedifficult to control foam generated by the reaction temperature and thefoaming agent. Note that, the aqueous solution of the present inventionmeans also dispersion liquid whose concentration exceeds the saturatedconcentration, but it is preferable that the polymerization is carriedout with the concentration below the saturated concentration. Thesaturated concentration is suitably determined by a kind of the monomerand a temperature of the aqueous solution.

Further, an organic solvent may be used together as a solvent for themonomer aqueous solution so that the monomer aqueous solution has afoaming function, and water and a water-soluble or dispersive organicsolvent may be used together. It is preferable that an amount of waterin the solvent preferably ranges from 90 to 100 wt %, particularlypreferably from 99 to 100 wt %. The polymerization temperature can beset in a range from 20 to 130° C., more preferably from 30 to 120° C.

In a method according to the present invention for producing a waterabsorbent resin, the unsaturated monomer may be made into particulatehydrogel by carrying out kneader polymerization or reverse phasesuspension polymerization at the time of polymerization. However, incase of carrying out still polymerization (stirless polymerization) suchas belt polymerization, the method may additionally include a gelgranulation step in which a clumpy hydrogel obtained in thepolymerization step is crushed into particulate hydrogel. The hydrogelis crushed into particulate hydrogel in this manner, so that a surfacearea of the gel increases. As a result, the below-described drying stepcan be smoothly carried out. The hydrogel can be crushed by variouscutting means such as a roller cutter, a guillotine cutter, a slicer, aroll cutter, a shredder, scissors, or by a combination thereof, and thecutting means is not particularly limited.

<Drying Step>

Next, the drying step is described as follows. The drying step is a stepof drying the hydrogel cross-linked polymer obtained in thepolymerization step, preferably, the particulate hydrogel obtained bycrushing the hydrogel in the gel granulation step. The drying method isnot particularly limited. For example, it is possible to favorably use aconventional method using one of or two or more devices out of a banddryer, a stirring dryer, and a fluidized-bed dryer.

A temperature at which the hydrogel cross-linked polymer is dried is notparticularly limited, but the drying temperature generally ranges from70 to 250° C., preferably 150° C. or higher and 230° C. or lower, morepreferably 160° C. or higher and 180° C. or lower. Note that, the dryingtemperature is defined by a heat medium temperature in case where a heatmedium is used in the aforementioned dryer. In case where the dryingtemperature cannot be defined by the heat medium temperature as in acase of a microwave for example, the drying temperature is defined by atemperature of the hydrogel cross-linked polymer. In case of carryingout high temperature drying (particularly at 250° C. or higher), theabsorbency may decrease. In case where the drying temperature exceeds250° C., the resin deteriorates. In the present invention, the hydrogelis dried preferably in the aforementioned temperature range so as toimprove the absorbency and provide a water absorbent resin having lessforeign matters.

In order to realize excellent property and maximize the effect of thepresent invention, a moisture content (defined by a loss from 1 g of aresin having been dried in an airless oven at 180° C. for three hours)of the dried polymer is preferably 90 mass % or more, more preferably 93mass % or more and 99.9 mass % or less, particularly preferably 95 mass% or more and 99.8 mass % or less.

The hydrogel cross-linked polymer having been subjected to the dryingstep is processed into a particulate form by carrying out abelow-described pulverizing step and a below-described classificationstep as necessary. Note that, a particle size of thus obtained particlesmay be controlled (sizing may be carried out) by granulation or byadding fine particles (e.g., fine particles whose particle diameter isnot more than 150 μm) having been removed in the classification step.

Note that, in the production method according to the present invention,the polymerization step and the drying step may be carried out in abatch manner or in a continuous manner. It is preferable to adoptcontinuous production including a transport step which links respectiveproduction steps. The continuous production will be detailed later.

<Properties of Water Absorbent Resin Powder>

The water absorbent resin powder produced by the water absorbent resinpowder production method according to the present invention is such thata mass average particle diameter defined by sieve classification ispreferably 200 μm or more and 10 mm or less, more preferably 300 μm ormore and 10 mm or less, (still more preferably 600 μm or less), and anamount of fine powder whose particle diameter is 150 μm is less than 10mass %, and has a surface cross-linked structure. That is, the waterabsorbent resin powder has less fine powder and is made up of fineparticles whose particle size is even, and has high water absorbingperformance. As described above, such high property water absorbentresin powder is likely to contain foreign matters, so that removal ofthe foreign matters through the below-described sorting step allowsproduction of water absorbent resin powder whose properties andwhiteness are high and which is less likely to be colored. Thus, such aremoval technique is very useful.

Further, the present invention using the color sorting technique can befavorably adopted to a polyhedral water absorbent resin (its massaverage particle diameter ranges from 2 to 10 mm and it is a tetrahedralto dodecahedral (preferably hexahedral) water absorbent resin) describedin U.S. Patent Publication No. 2007-041796. By adopting the presentinvention to the polyhedral water absorbent resin, it is possible toobtain water absorbent resin powder whose design is favorable and whichis suitable for display.

Note that, in the present specification, “mass” is a synonymous of“weight” and “mass %” is a synonymous of “weight %”. In view of theproperties, it is necessary that the mass average particle diameter(defined by sieve classification) of the water absorbent resin powder is200 μm or more and 10 mm or less, more preferably 300 μm or more and 10mm or less (still more preferably 600 μm or less), but the mass averageparticle diameter is preferably 350 μm or more and 550 μm or less, morepreferably 400 μm or more and 500 μm or less.

Further, in order to exhibit effect in actual use for a diaper or thelike, a logarithmic standard deviation (σζ) of particle sizedistribution preferably ranges from 0.10 to 0.45, more preferably from0.20 to 0.40, still more preferably from 0.27 to 0.37, particularlypreferably from 0.28 to 0.35.

It is necessary that an amount of fine powder whose particle diameter isnot more than 150 μm is 0 mass % or more and less than 10 mass %, butthe amount is preferably 0 mass % or more and less than 5 mass %, morepreferably 0 mass % or more and less than 3 mass %, still morepreferably 0 mass % or more and less than 1 mass %. These particlediameters and these amounts allow the water absorbent resin powder toexhibit high water absorbing performance. The fine powder decreases theperformance of the water absorbent resin and cannot be used as the waterabsorbent resin, so that the fine powder decreases the yield of thewater absorbent resin production. Thus, it is more preferable that asmaller amount of the fine powder is included.

A shape of each particle of the water absorbent resin powder may be anyone of a spherical shape, a cubic shape, a rectangular shape, a pillarshape, a plate shape, a scaly shape, a rod shape, a needle-like shape, afibrous shape, and the like. It is particularly preferable that thewater absorbent resin powder is made up of polyhedral particles orindefinite-shape pulverized particles obtained in the pulverization stepcarried out after the drying step. Further, the particles may begranulated particles or may be primary particles (non-granulatedparticles).

As long as the water absorbent resin powder obtained by the productionmethod of the present invention, it is possible to achieve such a highabsorbing performance that, for example, a centrifugal retentioncapacity (CRC) is 10 g/g or more, preferably 25 g/g or more, morepreferably 28 g/g or more, still more preferably 31 g/g or more,particularly preferably 34 g/g or more, and an absorbency againstpressure (AAP) (4.9 kPa) is preferably 20 g/g or more, more preferably23 g/g or more, still more preferably 25 g/g or more, and it is possibleto keep the high absorbing performance for an extended period of time.Note that, upper limits of the centrifugal retention capacity (CRC) andthe absorbency against pressure (AAP) are not particularly limited. Inview of a balance between other properties and the production cost, 80g/g or less, further, 60 g/g or less is sufficient as each of the upperlimits.

The water absorbent resin powder obtained by the production method ofthe present invention has the excellent water absorbing performance, anddeterioration of the excellent water absorbing performance is suppressedand is kept for an extended period of time, and the water absorbentresin powder has less foreign matters and has high whiteness. Thus, thewater absorbent resin powder can be favorably used as a sanitarymaterial though the use of the water absorbent resin powder is notlimited thereto. According to the present invention, it is possible toeasily produce the water absorbent resin powder having below-describedexcellent absorbing properties, so that the water absorbent resin powderis widely used in an agriculture/horticulture water retaining agent, anindustrial water retaining agent, a moisture absorbing agent, adehumidification agent, a display, an aromatic agent, a deodorant, abuilding material, and the like. Above all, the water absorbent resinpowder is favorably used particularly in a sanitary material forabsorbing feces, urine, and blood, e.g., in a sanitary napkin and thelike.

<Sorting Step>

Next, the sorting step is described as follows. The sorting step is aproduction step following to the drying step and is to carry out colorsorting with respect to entire parts or a part of the water absorbentresin so as to sort foreign matters included in the water absorbentresin. Note that, the color sorting of the present invention is suchthat colors of foreign substances (dark colors such as black, brown, anddark brown) are sorted and removed from a color of the water absorbentresin (white in general). The color of the water absorbent resinsubjected to the sorting step is not limited to complete white and maybe colored otherwise by any dye. Further, a part of the water absorbentresin may be yellowed due to its material. For example, YI (YellowIndex) of the water absorbent resin subjected to the sorting step ispreferably 70 or more, more preferably 80 or more, particularlypreferably 90 or more. Note that, the “YI” is defined in U.S. Pat. No.6,444,749 for example.

Further, it is preferable that values indicative of properties (solidcontent (moisture content), CRC, AAP, particle size, and the like) ofthe water absorbent resin subjected to the sorting step are in the valueranges described in (Properties of water absorbent resin), or in valueranges described in below (2. Particulate water absorbing agent).Further, the water absorbent resin subjected to the sorting step mayinclude additives described in the specification. Further, the particlesize of the water absorbent resin may be the same or may be changedbefore and after the sorting step.

As to the foreign matters to be removed, each particle thereof may beentirely colored or may be partially colored. In this manner, theforeign matters are sorted by setting a sorting condition suitably. Theproduction method according to the present invention is most favorablyused to remove dark color foreign matters included in white particles.

The foreign matters cannot be removed by repeating the process in thetechnique of Patent Document 6 in which metallic foreign substancesincluded in the water absorbent resin are removed by a magnetic line.The inventors of the present invention studied the cause thereof. As aresult, they found that the foreign matters are the water absorbentresin's parts burned in the production step. It was found that: parts ofthe water absorbent resin which adhere to a production device remain inthe device heated for a long time, and then the parts are dischargedfrom the device together with the water absorbent resin, so that theparts are mixed in the water absorbent resin as the foreign matters.However, the water absorbent resin is nonmagnetic, so that the foreignmatters derived from the water absorbent resin can not be removed by thetechnique of Patent Document 6 which adopts the magnetic line. Thus, theinventors of the present invention focused on the color sorting as themeans for removing the foreign matters.

In the color sorting, a sample color (bright) of a nondefective productis regarded as a background, and a color of a sample and the backgroundcolor are compared with each other by a sensor, and a signal at the timewhen the sensor monitors the background is set as a standard and acertain range is determined, and a signal deviating from the range isregarded as indicating a color difference, thereby removing defectiveproducts regarded as having a different color. The color sorting isfrequently used in a foreign substance removing step carried out withrespect to grains, beans, and the like. Examples thereof are exclusionof defective products, removal of sands and pebbles, and the like.

Conventionally, as described in Patent Documents 1 to 5, entireparticles have been focused on and a method for preventing browning oryellowing of the entire particles has been adopted, but it has not beenrecognized that the uncomfortable appearance in observing a waterabsorbent resin is caused by foreign matters, so that there was nofinding on the method for removing the foreign matters. Thus, theoptimal method has not been found. Also, it was found that: even if theconventional color indexes (YI value, Lab value) have favorable values,the indexes in some cases are not necessarily parameters suitable for avisual sense in an actual use. The inventors of the present inventionfound that the uncomfortable appearance is caused by the foreign matters(presence of several colored particles). As a result of diligent study,they found that the foreign matters are black or brown, so that theyfocused on the color sorting, thereby succeeding in efficient removal ofthe foreign matters.

The color sorting is such that a sensor determines whether there is anycoloring or not as described above, and the color sorting does notrequire a step of adding other component such as a chelating agent, anacid component, and the like unlike the technique described in PatentDocuments 1 to 5 for preventing the coloring. Thus, it is possible tocarry out the color sorting continuously with other steps, so that it ispossible to efficiently remove the foreign matters in an extremelysimple manner.

Next, with reference to FIG. 1, the sorting step is detailed as follows.FIG. 1 is a diagram schematically illustrating an arrangement of a colorsorting apparatus 1 used as an example of the present embodiment. Thecolor sorting apparatus 1 is not particularly limited, and aconventionally known apparatus can be used as the color sortingapparatus 1. Examples of the color sorting apparatus 1 are Kubotaparticulate foreign substance sorter PLATON (produced by KubotaCorporation), Magic Sorter (produced by SATAKE CORPORATION), Scanmaster(produced by SATAKE CORPORATION), and the like.

As illustrated in FIG. 1, the color sorting apparatus 1 includes afeeder 11, a chute 12, a sorting room 13, a sensor 14, a lamp 15, areflector 16, an air gun 17, a nondefective product collection cylinder18, and a defective product collection cylinder 19. The number ofchute(s) 12 can be set to one or more, preferably two to 100, dependingon a scale. Further, it is preferable to provide a dust collector so asto reduce dusts from the water absorbent resin.

The feeder 11 stores therein a water absorbent resin 100 having beensubjected to the drying step and supplies the water absorbent resin 100to the chute 12 while controlling an amount of the water absorbent resin100 flowed to the chute 12. A type of the feeder 11 is not particularlylimited, and it is possible to use an electromagnetic feeder, avibration feeder, a belt conveyer, and the like for example. The chute12 evenly flows, in a flat manner, the water absorbent resin 100supplied from the feeder 11. In view of improvement in the sortingefficiency, the water absorbent resin 100 is supplied in a form of asingle layer as much as possible.

The sorting room 13 includes the sensor 14 therein and serves as aportion which distinguishes the foreign matters from the flowing waterabsorbent resin 100. In the sorting room 13, the sensor 14, the lamp 15,and the reflector 16 are provided.

The sensor 14 senses the flowing water absorbent resin 100. The lamp 15illuminates the inside of the sorting room 13 so that the sensor 14 moreeasily observes the water absorbent resin 100. The reflector 16 servesas a background of the water absorbent resin 100 to be sensed. Thereflector 16 reflects a color (brightness) of a nondefective product,e.g., white (constant), and the sensor 14 compares a color of the waterabsorbent resin 100 entering the sorting room 13 with the color of thereflector 16. A signal at the time when the sensor 14 monitors thereflector 16 is regarded as a standard, and a certain range isdetermined, and a signal deviating from the range is determined to havea different color.

The sensor 14 is not particularly limited, and it is possible to use aconventionally known device such as a phototransistor, a solar battery,a camera, and the like. Examples of the camera include a line sensorcamera, an area sensor camera, a CCD camera, an NIR camera, and thelike. It is preferable to carry out a digital image process in the colorsorting because a sensor detection area can be narrower than that of ananalog signal process so that the foreign matters can be moreexclusively detected. Thus, the CCD camera is particularly favorablyused.

The camera may be a monochrome camera or may be a color camera. In caseof the color camera, the nondefective product and the defective productare distinguished on the basis of a color difference. In case of themonochrome camera, in order to distinguish the nondefective product andthe defective product, when brightness of the nondefective product andbrightness of the defective product are hardly different from eachother, a color filter is combined with the camera as required, therebyrecognizing a color difference as a brightness difference.

Note that, in the color sorting apparatus 1, whether or not to excludethe foreign matters may be determined in accordance with a size of thedetected foreign matters. In this case, a lower limit of the number ofpixels corresponding to the detected foreign substances which should beexcluded is set in the camera. Further, sensitivity of the camera can besuitably seta Herein, the sensitivity refers to a margin in determiningbrightness unevenness of the sort target as a foreign substance. Byadjusting the sensitivity, it is possible to control the accuracy andthe yield.

The lamp 15 is not particularly limited, and it is possible to use afluorescent lamp, a halogen lamp, a light emitting diode, and the like.The reflector 16 is suitably replaced as necessary so as to correspondto the color (brightness) of the water absorbent resin 100. If thebrightness of the reflector 16 is equal to the brightness of the waterabsorbent resin 100, it is possible to obtain a most favorable sortingresult. Generally, the color of the foreign matters is darker than thenondefective water absorbent resin, so that a white reflector is used.

A signal of the sensor 14 is amplified by an amplifier and is comparedby a comparator, and the air gun 17 is driven by a power circuit. Theair gun 17 emits an air jet to a falling defective product 102,determined as having a different color, so as to sort and remove thedefective product 102. The defective product 102 jetted away by the airgun 17 is collected into the defective product collection cylinder 19,and a nondefective product 101 which was not jetted away by the air gun17 is collected into the nondefective product collection cylinder 18. Inthe sorting step, the aforementioned operations are carried out at ahigh speed, so that it is possible to efficiently remove the foreignmatters.

Further, the removal by sorting is not limited to the method using theair gun 17, and it is possible to adopt a method in which the fallingdefective product 102 is adsorbed, a method in which the defectiveproduct 102 is scraped with a scraper, and a similar method. Note that,the sorting step may be carried out twice or more in order to moreaccurately remove the foreign matters. As to the sorting step, in viewof higher sorting efficiency, it is preferable to adopt a method usingcompressed air, e.g., the method using the air gun 17. The compressedair is preferably from 10 to 100000 Nl/min, more preferably from 100 to10000 Nl/min.

By carrying out the sorting step after the drying step, it is possibleto efficiently remove the foreign matters, so that it is possible toobtain a water absorbent resin, having a high properties, less foreignmatters, and high whiteness, which is less likely to be colored. Thesorting step is carried out at any timing as long as the sorting step iscarried out after the drying step, so that the sorting step can becarried out at an arbitrary stage after the drying step. However, it ispreferable to carry out the sorting step right before or right afterpackaging a final product, and it is particularly preferable to carryout the sorting step right before packaging the final product. Thesorting step may be incorporated into the production step of thecontinuous production. That is, the sorting step may be carried out inline of the production step. Further, the sorting step may be carriedout in a batch manner as required, apart from the production step.

Note that, a removal rate is suitably set depending on the yield, but itis difficult to selectively remove only the color particles at once, sothat it is general that 0.01 to 10 mass %, preferably 0.5 to 7 mass %,more preferably 0.1 to 5 mass % of the water absorbent resin subjectedto the sorting step is removed from the water absorbent resin subjectedto the sorting step. Further, it may be so arranged that sortedparticles including the foreign matters are further sorted so as toremove the foreign matters.

That is, it is preferable to carry out the color sorting plural times.Particularly, the water absorbent resin including the foreign matterswhich have been sorted once (first sorting) is further sorted (secondsorting), thereby improving the yield. A ratio of the first sorting andthe second sorting is suitably set so as to range from 10:0 (i.e., onlythe first sorting) to 5:5, preferably from 9:1 to 7:3.

For example, even if a ratio of the foreign matters to the entireparticles is 0.1 weight % or less, generally, 0.01 weight % or less,further, 0.001 weight % or less, particularly 0.0001 weight % or less,it is difficult to selectively remove the foreign matters from theentire particles. Thus, after removing particles whose amount is 5%(particles whose amount is excessively larger than the amount of theforeign matters; particles which are substantially white and partiallyinclude foreign matters), the water absorbent resin particles is 5% aresubjected to the second sorting (5%×5%), as necessary, are furthersubjected to third sorting (5%×5% 5%), and to fourth sorting, therebymaking the yield closer to 100%.

<Surface Treatment Step>

The surface treatment step is a step of carrying out a surface treatmentwith respect to the hydrogel cross-linked polymer or the dried polymer.In the present specification, the surface treatment refers to surfacecross-linking and/or surface coating carried out with respect to thehydrogel cross-linked polymer or the dried polymer.

[Surface Cross-Linking]

In order to improve the water absorbing performance, it is preferablethat the hydrogel cross-linked polymer is subjected to a surfacecross-linking treatment at a suitable stage before, during, or after thedrying step. The surface cross-linking treatment is carried out beforeand/or after the sorting step, preferably before the sorting step. Forexample, the surface cross-linking treatment is carried out by heating,preferably at 70° C. or higher and 250° C. or lower, more preferably150° C. or higher and 250° C. or lower, still more preferably 170° C. orhigher and 230° C. or lower, particularly preferably 180° C. or higherand 220° C. or lower, at the same time as the drying step or after thedrying step. Note that, the heating temperature is defined by a heatmedium temperature in case of using a heat medium in the dryer, but theheating temperature can be defined by a temperature of the hydrogelcross-linked polymer in case where the heating temperature cannot bedefined by the heat medium temperature, e.g., in case of using amicrowave.

The heating time is preferably one minute or more and three hours orless, more preferably five minutes or more and two hours or less, stillmore preferably 10 minutes or more and one hour or less. It is possibleto reduce particle adhesion in the drying step by adding the surfacecross-linking agent to the hydrogel cross-linked polymer which has notbeen dried and by drying the resultant mixture.

As a device for carrying out the aforementioned heating treatment, aknown dryer or a known oven is used. Favorable examples thereof includean electric heat conductive type dryer or oven, a radiation conductivetype dryer or oven, hot air conductive type dryer or oven, and adielectric heating type dryer or oven. Specific examples thereof includea belt type dryer or oven, a groove type stirring dryer or oven, a screwdryer or oven, a rotary dryer or oven, a disk dryer or oven, a kneadingdryer or oven, a fluidized-bed dryer or oven, an airflow dryer or oven,an infrared dryer or oven, and an electron dryer or oven.

Favorable examples of the surface cross-linking agent include: anoxazoline compound (U.S. Pat. No. 6,297,319), a vinyl ether compound(U.S. Pat. No. 6,372,852), an epoxy compound (U.S. Pat. No. 6,265,488),an oxethane compound (U.S. Pat. No. 6,809,158), a polyhydric alcoholcompound (U.S. Pat. No. 4,734,478), polyamidepolyamine-epihalo adduct(U.S. Pat. Nos. 4,755,562 and 4,824,901), hydroxyacrylamide compound(U.S. Pat. No. 6,239,230), an oxazolidinone compound (U.S. Pat. No.6,559,239), a bis or poly oxazolidinone compound (U.S. Pat. No.6,472,478), 2-oxotetrahydro-1,3-oxazolidinone compound (U.S. Pat. No.6,657,015), an alkylenecarbonate compound (U.S. Pat. No. 5,672,633), andthe like. These compounds are used independently or in a combination oftwo or more kinds. In addition to the surface cross-linking agent,water-soluble cation such as aluminum salt (U.S. Pat. Nos. 6,605,673,6,620,899) may be used, or alkali (U.S. Patent No. 2004-106745) andorganic acid or inorganic acid (U.S. Pat. No. 5,610,208) may be used.Further, it may be so arrange that a monomer is polymerized on a surfaceof the water absorbent resin so as to carry out surface cross-linking(U.S. Patent No. 2005-48221), or it may be so arranged that surfacecross-linking is carried out with a peroxide (U.S. Pat. No. 4,783,510).

Specific examples of the surface cross-linking agent include: polyhydricalcohols such as (di, tri, tetra, poly)ethyleneglycol, (di,poly)propyleneglycol, 1,3-propanediol, 2,2,4-trimethyl-1,3-pentandiol,(poly)glycerin, 2-butene-1,4-diol, 1,4-butandiol, 1,3-butandiol,1,5-pentandiol, 1,6-hexanediol, trimethylolpropane, di ortriethanolamine, pentaerythritol, and sorbitol; epoxy compounds such as(poly)ethyleneglycol diglycidyl ether, (di, poly)glycerol diglycidylether, (di, poly)propyleneglycol diglycidyl ether, and glycidol;multivalent amine compounds such as ethylenediamine, diethylenetriamine,triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, andpolyethyleneimine, and inorganic salts or organic salts thereof (forexample, azetidinium salt and the like); multivalent isocyanatecompounds such as 2,4-tolylenediisocyanate; multivalent oxazolinecompounds such as 1,2-ethylenebisoxazoline; alkylene carbonate compoundssuch as 1,3-dioxolane-2-one; a cyclic urea compound; a multivalent metalcompound such as aluminum sulfate; and the like.

Above all, it is preferable to use at least one kind of compoundselected from a group made up of the polyhydric alcohol compound, theepoxy compound, the polyvalent metal salt (preferably, aluminum salt),the polyhydric amine compound and salt thereof, and thealkylenecarbonate compound. Note that, in view of the effect, thesurface cross-linking may be carried out twice or more times. In thiscase, the second or further steps may be carried out by using the samesurface cross-linking agent as the first step, or may be carried out byusing a surface cross-linking agent different from the surfacecross-linking agent used in the first step.

Above all, the polyhydric alcohol compound has a high property and givesa plasticity to a surface of the water absorbent resin, so that it ispreferable to use the polyhydric alcohol compound as at least one ofsurface cross-linking treatment components so as to carry out thesurface cross-linking treatment.

In order to achieve the below-described properties, although dependingon compounds used or a combination thereof, an amount of the surfacecross-linking agent is preferably 0.001 parts by mass or more and 10parts by mass or less, with respect to 100 parts by mass of the waterabsorbent resin powder, and it is particularly preferable that its lowerlimit is 0.01 parts by mass and its upper limit is 5 parts by mass.

In carrying out the surface cross-linking, it is preferable to use wateras solvent to mix the water absorbent resin and the surfacecross-linking agent. Although depending on a type, a particle diameter,a moisture content, and the like of a water absorbent resin precursor,an amount of water used is preferably more than 0 part by mass and 20parts by mass or less, and more preferably 0.5 parts by mass or more and10 parts by mass or less, with respect to 100 parts by mass of solidcomponents of the water absorbent resin.

Further, at the time of the surface cross-linking, a hydrophilic organicsolvent may be used together as necessary in mixing the water absorbentresin and the surface cross-linking agent. With respect to 100 parts bymass of the water absorbent resin powder, an amount of the organicsolvent is preferably 0 part by mass or more and 20 parts by mass orless, more preferably 0 parts by mass or more and 10 parts by mass orless. It is most preferable not to use the hydrophilic organic solvent(substantially 0 part by mass).

In carrying out the surface cross-linking, it is preferable to adopt amethod in which water and/or the hydrophilic organic solvent and thesurface cross-linking agent are mixed in advance and then an aqueoussolution thereof is sprayed or dropped onto the water absorbent resinprecursor, and it is more preferable to mix them in a spraying manner.As to a size of the sprayed droplet, an average particle diameterthereof is preferably within a range from 0.1 to 300 μm, more preferablywithin a range from 0.1 to 200 μm.

[Addition of Additive]

In the present invention, if water-insoluble fine particles are used asthe additive apart from the surface cross-linking agent, it is possibleto improve a liquid permeability of the water absorbent resin, ananti-blocking property of the water absorbent resin at the time ofmoisture absorption, and a similar property. As the water-insoluble fineparticles, inorganic or organic water-insoluble fine particles whoseaverage particle diameter is preferably 10 μm or less, more preferably 1μm or less, particularly preferably 0.1 μm or less are used. Specificexamples thereof include metal soap, silicon oxide (product name:Aerosil made by Nippon Aerosil Co., Ltd.), titanium oxide, aluminumoxide, and the like. Mixing of the water-insoluble fine particles iscarried out by a method such as dry-blending or slurry blending. Anamount of the water-insoluble fine particles used is preferably not lessthan 10 parts by mass, more preferably 0.001 to 5 parts by mass, andstill more preferably 0.01 to 2 parts by mass, all with respect to 100parts by mass of the water absorbent resin.

In the present invention, in addition to the surface cross-linkingagent, other additives may be added as required. Examples of such otheradditives include: deodorant agents; antibacterial agents; fragrantmaterial; foaming agents; pigment; dye; hydrophilic staple fibers;plasticizers; adhesives; surfactants; fertilizer; oxidants; reducers;water; salt; chelating agents; disinfectants; hydrophilic polymers suchas polyethylene glycol and polyethylene imine; hydrophobic polymers suchas paraffin; thermo-plastic resins such as polyethylene andpolypropylene; and thermo-setting resins such as polyester resin andurea resin. These additives may be added in an adding step to impartvarious functions to the water absorbent resin. These additives are usedin an amount of generally 0 part by mass or more and 10 parts by mass ormore, preferably 0 part by mass or more and 1 part by mass or less.

The additives (water-insoluble fine particles; deodorant agents;antibacterial agents; fragrant material; foaming agents; pigment; dye;hydrophilic staple fibers; plasticizers; adhesives; surfactants;fertilizer; oxidants; reducers; water; salt; chelating agents;disinfectants; hydrophilic polymers such as polyethylene glycol andpolyethylene imine; hydrophobic polymers such as paraffin;thermo-plastic resins such as polyethylene and polypropylene; andthermo-setting resins such as polyester resin and urea resin; and thelike) may be added to an internal portion of the hydrogel cross-linkedpolymer or a dried resultant thereof, but it is preferable to coat asurface of the hydrogel cross-linked polymer or the dried resultantthereof. In the present specification, “surface coating” means to coatthe surface of the hydrogel cross-linked polymer or the dried polymerwith the additive without carrying out the cross-linking. For example,the surface coating is carried out as required in order to improve thefluidity or to achieve a similar object.

The surface treatment step covers a case where both the surfacecross-linking and the surface coating are carried out, a case where thesurface cross-linking is not carried out but the surface coating iscarried out, and a case where the surface coating is not carried out butthe surface cross-linking is carried out.

Note that, also the hydrogel cross-linked polymer having been subjectedto the surface treatment step and the dried polymer are sometimesreferred to as the water absorbent resin generically in the presentspecification.

<Continuous Production>

In the method according to the present invention for producing the waterabsorbent resin powder, the water absorbent resin having a large amountof foreign matters may be treated in a batch manner or may becontinuously treated. Preferably, after the drying step, a continuoustransport step which links the pulverization step, the classificationstep, and respective production steps is further included. That is, theproduction method according to the present invention can be favorablyapplied to a case of continuously producing the water absorbent resinpowder, particularly, a case of continuously producing the waterabsorbent resin powder for 30 days or more, further 60 days or more,moreover 120 days or more, particularly 240 days or more. Note that, thecontinuous production in the present invention corresponds to a periodin which articles having the same production number are continuouslyproduced, and corresponds to a time and day until which the productionnumber is changed or the production is temporarily stopped. Theproduction number is changed by suitably changing the productionconditions (the cross-linking agent and the amount thereof for example).

Further, the aforementioned “respective production steps” are notparticularly limited as long as the steps are carried out after thedrying step. For example, not only the surface treatment step and thesorting step, but also (i) steps for carrying out the above-describedgranulation, addition of the additives, sizing, and the like, (ii) ametallic foreign substance removal step described in a below-describedProduction Example 1 and Patent Document 6, (iii) and the like can becarried out as the “respective production steps”. A typical continuousflow of the continuous production is described in Patent Document 6,U.S. Pat. No. 6,727,345, U.S. Patent Publication No. 2004-110006, andthe like, and also the flow is favorably applicable to the presentinvention. For example, in case of carrying out the continuousproduction, it is possible to carry out the sorting step at least onceafter the drying step of such a flow.

Conventionally, the long-term continuous production is likely toincrease the amount of foreign matters as time goes on. Thus, it isnecessary to stop the production and to regularly repair the industrialplant. However, according to the present invention, such regular repairis not required and it is possible to continuously produce the waterabsorbent resin powder having high properties for an extended period oftime. Note that, the present invention is favorably applicable tolarge-scale continuous production of such a large amount of waterabsorbent resin powder that foreign matters are likely to occur, e.g.,100 Kg/hr or more, preferably 500 Kg/hr or more.

At the time of the continuous production, a large amount of foreignmatters are found in switching products, changing production conditions,and restarting the operation, so that an upper limit of the time periodin which the continuous production is carried out is not particularlylimited, but is preferably 1000 days or less, more preferably 800 daysor less, particularly preferably 500 days or less.

This is because: the foreign matters are carbonated which results fromsurface burning of the water absorbent resin due to long-time heathistory, and a part of the particles remains in the device (particularlyin a heated portion thereof) and then is discharged and mixed into theproduct, so that the foreign matters are likely to occur during theso-called continuous production including the drying step, thepulverization step, the classification step, and the continuoustransport step. Above all, the foreign matters are likely to occurparticularly in the drying step, the surface treatment step, or thecooling step thereof. Note that, the “cooling step” is a step ofstopping or controlling the cross-linking reaction by cooling, and isdescribed in U.S. Patent Publication No. 2004-181031 for example.

The pulverization step is a step of causing a pulverizer to pulverizethe dried hydrogel cross-linked polymer. Examples of the pulverizer usedin the pulverization step include a roller mill, a knife mill, a hummermill, a pin mill, various kinds of cutter, a jet mill, and the like. Itis preferable that the pulverizer includes means for heating an internalwall surface of the pulverizer itself. Note that, the “pulverization”means not only cutting the dried polymer into indefinite-shape piecesbut also cutting the dried polymer into polyhedral-shape pieces.

In the pulverization step, it is preferable that the internal wallsurface of the pulverizer is heated from the outside or an internal wallsurface temperature of the pulverizer is kept higher than a temperatureof the water absorbent resin by 20° C. or higher. This is because: thedried polymer particles obtained by carrying out the pulverizationadhere to the internal wall of the pulverizer and constitute a greateragglomerate, and the agglomerate falls off from the internal wall due tovibration of the pulverizer, so that the agglomerate is likely to bemixed into the product.

The classification step is a step of continuously classifying the driedpolymer particles obtained in the pulverization step. In theclassification step, although not limited, it is preferable to carry outsieve classification (using a metal sieve made of stainless steel). Fordesired properties and particle size, it is preferable to simultaneouslyuse a plurality of sieves in the classification step, and it ispreferable to carry out the sieve classification before the surfacecross-linking, further, twice or more times before and after the surfacecross-linking. In case of carrying out the sieve classification, it ispreferable to heat the sieve or to keep the sieve warm.

However, if the sieve classification is carried out at a hightemperature, a moisture content of the dried polymer powder decreases,so that the dried polymer powder becomes hard. As a result, the hardnessgreatly damages the sieve, so that fine metallic foreign substances maybe likely to be mixed into the dried polymer powder. Further, thelong-time heat history causes occurrence of the foreign matters. Thus,it is preferable to set a temperature of the sieve not to be high(preferably 40° C. or higher and 100° C. or lower, more preferably 50°C. or higher and 80° C. or lower).

The continuous transport step is a step of causing a transport apparatusor the like to continuously transport the dried polymer powder afterpulverizing the dried hydrogel cross-linked polymer (water absorbentresin). Examples of the transport apparatus used in the continuoustransport step include a belt conveyer, a screw conveyer, a chainconveyer, a vibration conveyer, a pneumatic conveyer, and the like, oran apparatus including means for heating its internal wall surface fromthe outside and/or means for keeping the internal wall surface warm.Above all, it is preferable to use the chain conveyer or the pneumaticconveyer. In the continuous transport step, in view of the conveyingproperty, higher one of (i) a temperature of the dried polymer powderand (ii) an internal temperature of the transport apparatus is set topreferably 40° C. or higher and 100° C. or lower, more preferably 50° C.or higher and 80° C. or lower. If the dried polymer powder is heated orkept warm in this manner, this improves the reactivity, but it was alsofound that this causes occurrence of the foreign matters when the driedpolymer powder remains.

As to the continuous transport step, it is preferable that at least apart thereof is carried out by pneumatic transport. Also in order toreduce damage (property decrease) of the dried polymer powder, i.e., thehigh-property water absorbent resin which is caused by the transport andalso in order to suppress the metallic foreign substances from beingmixed, it is preferable that a part of the continuous transport iscarried out by pneumatic transport. In the continuous transport step, itis preferable that the internal wall surface of the transport apparatusis heated from the outside and/or the internal wall surface is keptwarm. This is because such arrangement is likely to effectively preventformation of the agglomerate.

Note that, the “pneumatic transport” is disclosed by U.S. PatentPublication No. 2004-345804, U.S. Patent Publication No. 2004-242761,U.S. Patent Publication No. 2005-113252, and the like.

A timing at which the sorting step is carried out is not particularlylimited as long as the sorting step is carried out after the dryingstep. For example, the sorting step may be carried out during thepulverization step, the classification step, and the continuoustransport step, after the drying step, or may be carried out rightbefore or right after packaging the final product. Further, the sortingstep may be carried out plural times and may be carried out at pluralstages in the production steps. Above all, the foreign matters are morelikely to occur in latter stages of the production steps, and theforeign matters are likely to occur particularly in a surfacecross-linked product, so that it is preferable to carry out the sortingstep after the surface cross-linking, particularly after theclassification after the surface cross-linking, further, right before orright after packaging the final product.

Note that, it is not necessary to carry out the color sorting withrespect to the entire amount of the water absorbent resin, and a Lot inwhich foreign matters occurred is selected and the color sorting iscarried out with respect to only the selected Lot. Further, the colorsorting may be carried out only when any trouble happens in theproduction steps or may be carried out when foreign matters begin tooccur with long-time continuous production. Furthermore, the colorsorting may be carried out with respect to only a packaged product (acontainer or a bag) in which foreign matters were found after packagingeach product.

Further, a color (black foreign substance) of the foreign matter havinga greater particle diameter is visually more conspicuous, and theforeign matter can be easily removed by the color sorting, so that aremoval rate is improved. Thus, it is preferable not to carry out thecolor sorting with respect to the whole water absorbent resin but tocarry out classification with respect to the water absorbent resin andcarry out the color sorting with respect to only large particles.Further, it was found that relatively small particles have less foreignmatters. Also from such a view point that it is not efficient to carryout the color sorting with respect to the whole particles and such colorsorting decreases the yield, it is preferable to carry outclassification with respect to the water absorbent resin and to carryout the color sorting with respect to only large particles.

Specifically, the color sorting is carried out with respect to onlyparticles whose particle diameter is 300 μm or more, more preferably 600μm or more, particularly preferably 850 μm or more, defined by standardsieve classification, thereby carrying out efficient color sorting.Further, not only entirely color particles but also partially colorparticles, e.g., large particles having a mm order, may be sorted.

Note that, the water absorbent resin is temporarily stored in a hopperor the like as necessary after the color sorting and then is packaged,but a package style of a final product is not particularly limited aslong as the package allows non-water-permeable andnon-moisture-permeable sealing. For example, a container or a bag can beused, and a content of each package generally ranges from 20 Kg to 20000Kg, more preferably from 100 Kg to 10000 Kg, particularly preferablyfrom 500 Kg to 5000 Kg.

A large number of agglomerates are colored, and as described above, thecolor sorting apparatus 1 may determine whether or not to exclude theagglomerates depending on the size of the foreign matter, so that thesorting step may be carried out with respect to only water absorbentresin having a rough particle size. Of course, the sorting step may becarried out with respect to the entire amount. The sorting step iscarried out with respect to only particles having a rough particle sizein case of providing water absorbent resin remaining on the sieve in theclassification step for example (e.g., water absorbent resin whoseparticle diameter is 850 μm or more defined in standard sieveclassification) or in a similar case.

The water absorbent resin sorted as a defective product in the sortingstep may be further subjected to the sorting step repeatedly for higherpurity. The water absorbent resin finally sorted as a defective productmay be removed and may be used for purpose which requires no whiteness,e.g., for a soil water retaining agent, a waste fluid solidifying agent,and the like. However, the water absorbent resin is preferably subjectedto a re-treatment step of breaching out the water absorbent resin.

As the breaching-out method, a conventionally known method can be used,and the breaching-out method is not particularly limited. For example,it is possible to breach out the water absorbent resin by usingchlorine, alkali, enzyme, and the like. Other example of the method forre-treating the water absorbent resin sorted as a defective product is amethod in which gelatinization with a monomer causes the amount of theforeign matters to be not more than the detection limit.

Further, the method according to the present invention for producingwater absorbent resin powder may include a metallic foreign substanceremoval step which causes a magnetic field whose magnetic flux densityis 0.05 Wb/m² or more to pass through the water absorbent resin inproduction steps carried out after the drying step. The metallic foreignsubstance removal step is a step of causing a magnetic field to passthrough a fixed or moving water absorbent resin, preferably acontinuously flowing water absorbent resin, more preferably acontinuously transported water absorbent resin. The water absorbentresin is subjected to the step, so that it is possible to efficientlyremove metallic foreign substances included in the water absorbentresin. As a result, it is possible to keep the high properties of thewater absorbent resin. Note that, as the metallic foreign substanceremoval step, a method described in Patent Document 6.

(2. Particulate Water Absorbing Agent)

The particulate absorbing agent in the present invention refers to anaqueous liquid absorbing and solidifying agent including a waterabsorbent resin (as a main component) and preferably contains a specificamount of water (moisture content ranges from 0.5 to 20 mass %,preferably from 1 to 15 mass %, particularly preferably from 2 to 10mass %). The aqueous liquid absorbing and solidifying agent containswater, so that it is possible to improve a water absorbing rate and acrashproof property, and it is possible to realize higher properties,and it is possible to at least keep the property from decreasing. Notethat, in the present specification, the “particulate water absorbingagent” is a synonymous of the “water absorbent resin powder” in casewhere a below-described “(g) Other additives” are not included.

An amount of the water absorbent resin included in the particulate waterabsorbing agent is not particularly limited, but generally ranges from70 to 100 mass %, preferably from 70 to 98 mass %, more preferably from80 to 98 mass %, particularly preferably from 90 to 98 mass %, withrespect to the entire amount of the particulate water absorbing agent.

Further, the particulate water absorbing agent may contain the abovedescribed additives as required. Note that, the aqueous liquid is notlimited to water, but may be urine, blood, feces, waste fluid, moisture,vapor, ice, a mixture of water and organic solvent, a mixture of waterand inorganic solvent, rain water, ground water, and the like, as longas the aqueous liquid includes water. It is preferable that theparticulate water absorbing agent is an absorbing and solidifying agentwhich absorbs and solidifies urine, particularly human urine, out of theaforementioned aqueous liquids.

An Example of Production Method of Particulate Water Absorbing Agent

The particulate water absorbing agent can be obtained by a productionmethod including the following steps (A) to (E) for example.

(A) A step of preparing a monomer component in which acrylic acid and/orsalt thereof is contained as a main component and at least a part of theacrylic acid salt is ammonium salt and/or amine salt.

(B) A step of carrying out aqueous solution polymerization with respectto the monomer component by using an azo polymerization initiator.

(C) A step of obtaining dried powder in which an amount of particleshaving a particle diameter less than 150 μm is 0 mass % or more and 5mass % or less and a mass average particle diameter (D50) is 200 μm ormore and 450 μm or less and a logarithmic standard deviation (σζ) is0.20 or more and 0.40 or less, after the polymerization.

(D) A step of carrying out surface cross-linking with respect to thepowder.

(E) A step of carrying out color sorting with respect to the surfacecross-linked powder.

Note that, the aforementioned production method is an example, and theproduction method is not limited to the aforementioned production methodas long as the particulate water absorbing agent satisfies the followingproperties (1) to (3). The particulate water absorbing agent obtained bythe above-exemplified production method is a novel particulate waterabsorbing agent having high properties and excellent white appearance.Note that, substantially nothing other than the amount of the foreignmatters changes before and after the color sorting, so that the waterabsorbent resin having the specific properties, i.e., the highproperties is obtained and the water absorbent resin is subjected to thecolor sorting in the present invention.

That is, the particulate water absorbing agent includes the waterabsorbent resin produced by the production method according to thepresent invention, and satisfies the following conditions (a) to (c).

(a) An absorbency against pressure (AAP: 0.90 g) is 20 g/g or more and60 g/g or less.

(b) An amount of contained foreign matters is 5 mm²/100 g or less.

(c) An amount of particles having a particle diameter less than 150 μmis 0 mass % or more and 5 mass % or less and a mass average particlediameter (D50) is 200 μm or more and 550 μm or less and a logarithmicstandard deviation (σζ) of particle size distribution is 0.20 or moreand 0.40 or less.

As to an absorbency in 0.90 mass % sodium chloride aqueous solutionagainst a pressure of 4.8 kPa for 60 minutes, an absorbency of 0.9 g ofthe particulate water absorbing agent is (AAP: 0.90 g).

It is preferable that the water absorbent resin is obtained bypolymerizing a monomer including an acrylic acid salt monomer as a maincomponent. By using the acrylic acid salt monomer, it is possible tofurther improve the water absorbing performance and the safety of theresultant hydrogel, so that it is possible to improve the waterabsorbing performance and the safety of the particulate water absorbingagent including the water absorbent resin. The water absorbent resinbefore or after the color sorting preferably has below describedproperties “(a) PPUP”, “(c) Particle size in standard sieveclassification”, “(d) Absorbency against pressure”, and “(e) Centrifugalretention capacity (GVs) and extractable polymer content”. Further, anamount of the foreign matters included in the water absorbent resinhaving been subjected to the color sorting is described inbelow-described “(b) Foreign matters”. The properties are suitablyadjusted in the aforementioned steps such as the polymerization step,the pulverization step, and the surface cross-linking step, and thelike.

(a) PPUP (Permeability Potential Under Pressure)

As to the particulate water absorbing agent, its permeability potentialunder pressure (PPUP) is preferably 50% or more and 100% or less, morepreferably 60% or more and 100% or less, most preferably 70% or more and100% or less. Note that, unlike the absorbency against pressure (AAP:0.9 g), the permeability potential under pressure is an index indicativeof stability (less decrease) of the absorbency against pressure (AAP) inincreasing an amount of the water absorbent resin (an amount of resinfor each measured area) from 0.90 g to 5.0 g.

For example, the amount of the water absorbent resin (an amount of resinfor each measured area) varies depending on a portion in a diaper, sothat variation of the absorbency against pressure (AAP) which is causedby variation of the amount of the resin causes properties of the diaperin actual use to decrease. In case where the PPUP is extremely high, itis possible to stably exhibit high properties regardless of the amount(concentration) of the water absorbent resin in the diaper, and it ispossible to exhibit higher liquid permeability. The permeabilitypotential under pressure (PPUP) is detailed in Japanese UnexaminedPatent Publication No. 2005-109779 (filed on Apr. 6, 2005, correspondingto WO2006-109844), and such description is applied to the presentinvention.

(b) Foreign Matters

In the particulate water absorbing agent, after the color sorting, theamount of the foreign matters is preferably 5 mm²/100 g or less, morepreferably 3 mm²/100 g or less, most preferably 1 mm²/100 g or less andsubstantially 0 (undetectable). The foreign matters whose amount is 5mm²/100 g or less are hardly observed by eyes, so that this value isimportant in view of a critical point when the particulate waterabsorbing agent is actually used for a diaper and the like. Within therange, the foreign matters do not show any uncomfortable appearance tothe consumer even though the foreign matters are included in a whitepulp of a diaper, a napkin, or the like. The water absorbent resin usedin the particulate water absorbing agent can be obtained by the methodaccording to the present invention for producing the water absorbentresin and is subjected to the aforementioned sorting step, so that theamount of the foreign matters contained in the particulate waterabsorbing agent is extremely small. Thus, the particulate waterabsorbing agent has excellent whiteness and is less likely to becolored.

(c) Particle Size in Standard Sieve Classification

In view of the properties, it is necessary that a mass average particlediameter (D50) of the particulate water absorbing agent is 200 μm ormore and 10 μm or less, further 300 μm or more and 10 μm or less(preferably 600 μm or less). However, the mass average particle diameter(D50) is preferably 350 μm or more and 550 μm or less, more preferably400 μm or more and 500 μm or less. Particularly in case where theparticulate water absorbing agent is used for a sanitary material suchas a diaper, particles having other particle size are mixed or separatedas required, thereby adjusting the mass average particle diameter (D50)to 200 μm or more and 550 μm or less, preferably 250 μm or more and 500μm or less, more preferably 300 μm or more and 450 μm or less,particularly preferably 350 μm or more and 400 μm or less. The particlesize can be controlled not only in the pulverization step and theclassification step but also in the sorting step as necessary.

Further, it is more preferable that an amount of fine powder whoseparticle diameter is 150 μm or less (defined by standard sieveclassification) is smaller. The amount of the fine power is adjusted togenerally 0 mass % or more and 5 mass % or less, preferably 0 mass % ormore and 3 mass % or less, particularly preferably 0 mass % or more and1 mass % or less.

Further, it is more preferable that an amount of particles whoseparticle diameter is 850 μm or less (defined by standard sieveclassification) is smaller. The amount of the particles is adjusted togenerally 0 mass % or more and 5 mass % or less, preferably 0 mass % ormore and 3 mass % or less, particularly preferably 0 mass % or more and1 mass % or less. The logarithmic standard deviation (σζ) of particlesize distribution is 0.10 or more and 0.45 or less, preferably 0.20 ormore and 0.40 or less, more preferably 0.27 or more and 0.37 or less,further more preferably 0.25 or more and 0.35 or less.

In case where the logarithmic standard deviation (σζ) deviates from theforegoing particle size distribution, the particulate water absorbingagent exhibits less effect in being used as an absorbing article such asa disposable diaper or the like. The particle size is suitably adjustedby carrying out pulverization, classification, fine powder collection,granulation, and the like.

Further, a bulk density (defined by JIS K-3362) of the particulate waterabsorbing agent is preferably 0.40 g/ml or more and 0.90 g/ml or less,more preferably 0.50 g/ml or more and 0.80 g/ml or less.

(d) Absorbency Against Pressure (AAP)

With respect to physiological saline, the particulate water absorbingagent has an absorbency against pressure (4.8 kPa: 0.90 g) of preferably15 g/g or more, more preferably 20 g/g or more, more preferably 23 g/gor more, still more preferably 25 g/g or more. Further, also anabsorbency against pressure (1.9 kPa: 0.90 g) with respect tophysiological saline is generally 15 g/g or more, preferably 20 g/g ormore, more preferably 25 g/g or more, still more preferably 28 g/g ormore, particularly preferably 32 g/g or more. An upper limit of eachabsorbency against pressure is not particularly limited, but isgenerally about 60 g/g in view of (i) balance with other properties and(ii) cost performance.

(e) Centrifugal Retention Capacity (GVs) and Extractable Polymer Content

The particulate water absorbing agent has a centrifugal retentioncapacity (GVs: referred to also as CRC) of 10 g/g or more and 50 g/g orless, preferably 28 g/g and 50 g/g or less, more preferably 28 g/g ormore and 45 g/g or less, still more preferably 30 g/g or more and 45 g/gor less, particularly preferably 30 g/g or more and 40 g/g or less. WhenCRC is excessively high, other properties decrease, e.g., a gelstrength, urine-proof property, and the like decrease. When CRC isexcessively low, an absorption amount is not sufficient in beingactually used for a diaper. Further, the extractable polymer content ispreferably 0 mass % or more and 25 mass % or less, more preferably 0mass % or more and 15 mass % or less, still more preferably 0 mass % ormore and 10 mass % or less.

(f) Residual Monomer

Further, an amount of the residual monomer of the particulate waterabsorbing agent is 0 mass ppm or more and 400 mass ppm or less, morepreferably 0 mass ppm or more and 300 mass ppm or less, particularlypreferably 0 mass ppm or more and 200 mass ppm or less, most preferably0 mass ppm or more and 100 mass ppm or less. Such a residual monomer isachieved by carrying out neutralization with ammonium or by using an azopolymerization initiator for example.

(g) Other Additives

Further, in order to provide various functions as a required function,the particulate water absorbing agent may include: water-insolubleinorganic or organic powder, e.g., a chelating agent. (exemplified inU.S. Pat. No. 6,599,989 for example), an oxidizing agent (exemplified inU.S. Patent Publication No. 2006-183828 for example), a reducing agentsuch as bisulfite (hydrogen) salt (exemplified in U.S. Pat. No.4,863,989 for example), a chelating agent such as aminocarboxylate(exemplified in U.S. Pat. No. 6,469,080 for example), silica and metalsoap (exemplified in U.S. Patent Publication No. 2005-0118423), and thelike; a surfactant (exemplified in U.S. Pat. No. 6,107,358 for example);deodorant; an antibacterial agent; polymer polyamie; pulp; thermoplasticfiber; and the like so that an amount thereof is 0 mass % or more and 3mass % or less, preferably 0 mass % or more and 1 mass % or less.

A moisture content (100−solid content (%)) of the particulate waterabsorbing agent is 0.1 mass % or more and 12 mass % or less, preferably2 mass % or more and 10 mass % or less, more preferably 2 mass % or moreand 8 mass % or less, still more preferably 2 mass % or more and 7 mass% or less, particularly preferably 2 mass % or more and 6 mass % orless, most preferably 2 mass % or more and 5 mass % or less. If themoisture content deviates from the range of from 0.1 mass % to 12 mass%, the water absorbing agent is inferior in powder properties (fluidity,transportability, and anti-damage property).

In the present invention, the water absorbent resin powder obtained bypolymerizing an unsaturated monomer containing acrylic acid and/or saltthereof as a main component is packaged in a non-permeable bag or anon-permeable container, and each package contains 20 Kg to 200000 Kg ofthe water absorbent resin powder, and the water absorbent resin powdersatisfies the following conditions (a) to (c).

(a) An absorbency under load (AAP: 0.90 g) is 20 g/g or more and 60 g/gor less.

(b) An amount of contained foreign matters is 5 mm²/100 g or less.

(c) An amount of particles having a particle diameter less than 150 μmis 0 mass % or more and 5 mass % or less and a mass average particlediameter (D50) is 200 μm or more and 550 μm or less and a logarithmicstandard deviation (σζ) of particle size distribution is 0.20 or moreand 0.40 or less.

As to an absorbency in 0.90 mass % sodium chloride aqueous solutionunder a load of 4.8 kPa for 60 minutes, the absorbency of 0.9 g of theparticulate water absorbing agent is (AAP: 0.90 g).

The package of the water absorbent resin powder has a small amount offoreign matters in view of a critical point, so that the foreignmatters, are not observed by eyes and the properties are high. Thus, thepackage is favorably applicable to industrial production of finalconsumer products such as diapers.

The package of the water absorbent resin powder is characterized notonly in its high properties but also in its production volume of notless than 100 Mton (Mton=Metric ton=1000 kg). Conventionally, when alarge amount of the water absorbent resin powder is industriallyproduced unlike laboratory-level production, problems such asincorporation of foreign matters and lower properties occur. However,the present invention can provide the water absorbent resin powder whichis free from any foreign matters even if 100 Mton or more of the waterabsorbent resin powder is industrially produced. Thus, it is possible toprovide the high-property water absorbent resin powder which is suitablefor mass consumption and free from any foreign matters and whichexhibits high properties in a diaper and does not have uncomfortableappearance derived from the foreign matters. The production volume is,in total, 100 Mton or more, preferably 1000 Mton or more, morepreferably 10000 Mton or more, still more preferably a total productionvolume, particularly preferably an annual production volume.

(3. Purpose of Use)

The purpose of use of the water absorbent resin powder and theparticulate water absorbing agent which are produced by the method ofthe present invention for producing the water absorbent resin powder isnot particularly limited as described in the <Properties of waterabsorbent resin powder>. However, it is preferable to use the waterabsorbent resin powder and the particulate water absorbing agent forabsorbing articles such as a disposable diaper, a sanitary napkin, andan incontinence pad. Particularly, the water absorbing agent has highproperties and excellent whiteness and is less likely to be colored, sothat the water absorbing agent is favorably used for a highconcentration diaper (a diaper containing a large amount of waterabsorbent resin) which conventionally raised problems such as odorderived from a material of the water absorbing agent and uncomfortableappearance caused by foreign substances. Particularly, in case where thewater absorbing agent is used for an absorbent core top layer of theabsorbing article, it is possible to exhibit particularly excellentproperties. The water absorbent resin powder according to the presentinvention or the water absorbent resin powder obtained by the productionmethod according to the present invention does not show uncomfortableappearance to the consumer even when the water absorbent resin powder isin a white pulp.

The absorbing article includes: (a) the particulate water absorbingagent, (b) an absorbent core obtained by forming a hydrophilic fiberinto a sheet shape as required, (c) a liquid permeable front sheet, and(d) a liquid impermeable back sheet. The absorbent core in case wherethe hydrophilic fiber is not used is arranged by fixing the waterabsorbing agent onto paper and/or nonwoven fabric.

The absorbing article, including child diapers, adult diapers, andsanitary napkins, are produced in the following manner: The particulatewater absorbing agent is blended or sandwiched with a fiber basematerial, for example, a hydrophilic fiber, to form an absorbent core.The absorption core is then sandwiched between a liquid permeable basematerial (front sheet) and a liquid impermeable base material (backsheet). Thereafter, an elasticity member, a diffusion layer, and/oradhesive tape is fitted if necessary.

The absorbent core contains the particulate water absorbing agent at anamount (core concentration) of 30 mass % or more and 100 mass % or less,preferably 40 mass % or more and 100 mass % or less, more preferably 50mass % or more and 100 mass % or less, still more preferably 60 mass %or more and 100 mass % or less, particularly preferably 70 mass % ormore and 100 mass % or less, most preferably 75 mass % or more and 95mass % or less. For example, in case of using the particulate waterabsorbing agent with the aforementioned concentration, particularly incase of using the particulate water absorbing agent for an absorbentcore top layer, high permeability (permeability potential underpressure) results in an excellent diffusion property with respect toabsorbed liquid such as urine, so that it is possible to provide anabsorbing article such as a disposable diaper whose absorption amount isincreased due to efficient liquid distribution and whose absorbent corekeeps its sanitary whiteness.

Further, it is preferable that the absorbent core is compression moldedto a density of 0.06 g/cc or more and 0.50 g/cc or less and a basicweight of 0.01 g/cm² or more and 0.20 g/cm² or less. The fiber basematerial used is, for example, crushed wood pulp or a hydrophilic fibersuch as a cotton linter, a cross-linked cellulose fiber, rayon, cotton,wool, acetate, or vinylon. These fiber base materials are preferablyaerated.

Note that, the present invention is not limited to the description ofthe embodiments above, but may be altered by a skilled person within thescope of the claims. An embodiment based on a proper combination oftechnical means disclosed in different embodiments is encompassed in thetechnical scope of the present invention.

EXAMPLES

Through the following examples and comparative examples, the presentinvention is described more specifically. However, the present inventionis not limited to the following examples and the like, as long as thepresent invention is interpreted in light of a gist thereof. Note that,properties of the particulate water absorbing agent were measured in thefollowing measurement methods.

(1) Centrifugal Retention Capacity (Absorbency without any Pressure in30 Minutes with Respect to 0.90 Mass % of Sodium Chloride AqueousSolution (CRC))

0.200 g of water absorbent resin powder was evenly contained in a bag(60 mm×60 mm) made of a nonwoven fabric at room temperature (20° C. orhigher and 25° C. or lower) and at a humidity of 50 RH %. Then, the bagwas soaked in 0.90 mass % physiological saline whose temperature was aroom temperature, and was withdrawn 30 minutes later. By using acentrifugal separator (centrifugal machine made by KOKUSAN Corporation:model type is H-122), the bag was drained for three minutes at 250G, anda weight W1 (g) of the bag was measured. Further, the same operation wasperformed without using the water absorbent resin powder or the waterabsorbing agent, and a mass W0 (g) was measured. Then, from the massesW1 and W0, a centrifugal retention capacity (CRC) (g/g) was calculatedaccording to the following equation.Centrifugal retention capacity (g/g)=((mass W1 (g)−mass W0 (g))/mass (g)of water absorbent resin powder)(2) Extractable Polymer Content (Quantity of Water-Soluble Component)

500 mg of the water absorbent resin powder was dispersed into 1000 g ofion exchange water poured in a propylene cup (internal diameter 90mm×200 mm) having a cover, and the ion exchange water was stirred for 16hours by using a 4 cm-magnetic stirrer at about 300 to 600 rpm. Then,the hydrogel dispersion liquid was filtered through a piece of filterpaper (product of Advantec Toyo Kaisha, Ltd.; product name: JIS P3801,No. 2; thickness: 0.26 mm; diameter of retained particles: 5 μm),thereby obtaining a filtrate.

Next, 50.0 g of the filtrate was measured and poured into a 100 mlbeaker, and 1 ml of 0.1N-sodium hydrate aqueous solution (product ofWako Pure Chemical Industries, Ltd.), 10 ml of 0.005N-methylglycolchitosan aqueous solution (product of Wako Pure Chemical Industries,Ltd.), and about 0.2 g of 0.1% toluidine blue (toluidine blue pHindicator produced by Wako Pure Chemical Industries, Ltd.) were added tothe filtrate.

Subsequently, the solution of the beaker was subjected to colloidaltitration by using 0.0025N-polyvinyl potassium sulfate aqueous solution(product of Wako Pure Chemical Industries, Ltd.), and the titration wasfinished at the time when a color of the solution changed from blue topurplish red, and then a titration amount D (ml) was measured. Further,the same operation was carried out by using 50 g of ion exchange waterinstead of 50 g of the filtrate, thereby measuring a titration amount E(ml).

From these titration amounts and an average molecular weight F of themonomer constituting the water absorbent resin powder, an amount of theextractable polymer content (mass %) was calculated in accordance withthe following equation.Extractable polymer content (mass %)=(E (ml)−D (ml))×0.005/C(g)×F(3) Residual Monomer Amount (Residual Acrylic Acid Amount)

In the operation (2), the ion exchange water was stirred for two hoursand was filtered in the same manner, and residual acrylic acid in thefiltrate was analyzed in a liquid chromatography.

(4) Mass Average Particle Diameter

The water absorbent resin powder was sieved by using JIS standard sieves(JIS Z8801-1 (2000)) respectively having mesh sizes of 850 μm, 600 μm,500 μm, 425 μm, 300 μm, 212 μm, 150 μm, 106 μm, 75 μm, and the like, anda residual percentage R was plotted on a logarithmic probability paper.Then, a mass average particle diameter (D50) thereof was read. Notethat, the mesh size was suitably changed so as to correspond to theparticle diameter. For example, as to particles whose particle diameteris 1 mm or more, it is possible to use a sieve or the like described inU.S. Patent Publication No. 2007-041796.

Note that, conditions of the classification were as follows: 10.0 g ofthe water absorbent resin powder was spread on JIS standard sieves (THEIIDA TESTING SIEVE: diameter is 8 cm), and was classified by using asieve shaker (IIDA SIEVE SHAKER, TYPE: ES-65, SER. No. 0501) for tenminutes at the room temperature (20° C. or higher and 25° C. or lower)under the humidity of 50 RH %.

(5) Amount of Included Foreign Matters

An amount of foreign matters (mm²/100 g) included in the water absorbentresin powder was measured in accordance with JIS P8208 (1998) “paperpulp foreign matter testing method”. That is, “foreign mattermeasurement table (Bureau of Engraving and Printing; sold by ChoyokaiCo., Ltd. (Kitaku, Tokyo)) and “foreign matter measuring apparatus”mentioned in JIS P8208 were used, and 14 drawings whose display areasizes range from 0.05 mm² to 5.0 mm² defined in the foreign mattermeasurement table (made of transparent polyester film) were respectivelyoverlapped on the water absorbent resin power, thereby selecting adrawing most approximate to the size and the shape of the waterabsorbent resin powder. Then, an area size of the foreign matters wascompared and calculated on the basis of a total of the display areasizes (for example, in case where 10 foreign matters whose area size is0.05 mm² are found in 100 g of the water absorbent resin powder, this isexpressed as 0.5 mm²/100 g). Note that, according to JIS P8208, dustsand shive which are included in a pulp are collectively referred to as“foreign matters”, and the foreign matters are not transparent or havecolors different from other portions. However, in the presentapplication, color particles (generally black or brown) which can bedistinguished by eyes from the water absorbent resin powder (generallywhite, e.g., YI≤20) on the basis of JIS P8208 are defined as the foreignmatters.

(6) How to Measure Absorbency Against Pressure (AAP)

In accordance with a method disclosed in Examples of European Patent No.0885917 and European Patent No. 0811636, the water absorbent resinpowder's absorbency with respect to a physiological saline against apressure of 4.9 kPa (about 50 g/cm²) was measured. That is, with a loadof 50 g/cm² being evenly applied, a mass W2 (g) of the physiologicalsaline absorbed by 0.900 g of the water absorbent resin powder wasmeasured by using a scale. Further, from the mass W2, the absorbencyagainst pressure (g/g) of the water absorbent resin powder havingabsorbed the physiological saline for 60 minutes was calculatedaccording to the following equation. In this way, the absorbency againstpressure (50 g/cm²) was obtained.Absorbency against pressure (g/g)=mass W2 (g)/mass (g) of waterabsorbent resin powder(7) Permeability Potential Under Pressure (PPUP)

The same operation as in measurement (6) of the absorbency againstpressure (AAP: 0.90 g) with the load of 4.9 kPa was carried out exceptthat the amount of the water absorbent resin powder was changed from0.900 g to 5.000 g, thereby calculating an absorbency against pressure(AAP: 5.0 g). At this time, if the absorbency against pressure (AAP: 5.0g) is higher, a layer height of the swollen water absorbent resin (orparticulate water absorbing agent) is likely to increase, so that it isnecessary that a support cylinder used in this operation is sufficientlyhigh. The absorbency against pressure (AAP: 0.90 g) and the absorbencyagainst pressure (AAP: 5.0 g) were used, thereby calculating thepermeability potential under pressure (PPUP) in accordance with thefollowing equation.Permeability potential under pressure (PPUP) (%)=(AAP: 5.0 g (g/g)/AAP:0.90 g (g/g))×100(8) Coloring of Water Absorbent Resin Powder

A spectral color-difference meter SZ-Σ80 COLOR MEASURING SYSTEM (productof NIPPON DENSYOKU KOGYO) was used to measure an object color of thewater absorbent resin powder (about 5 to 10 g) right after productionthereof under preset conditions (reflection condition/powdery paste testtable (internal diameter: 30 nm)/powdery paste standard white plate No.2 as a standard/projector pipe of 304)). Note that, a promotion test ofU.S. Patent No. 20040110914 was not carried out. As YI is smaller, thewhiteness is higher. It is preferable that Yi is 15 or less, and it ismore preferable that Yi is 10 or less.

(9) Saline Flow Conductivity

The saline flow conductivity (SFC) of 0.69 mass % physiological salinewas measured on the basis of a physiological saline flow conductivitytest described in U.S. Patent No. 2004-0106745.

By using an apparatus described in U.S. Patent No. 2004-0106745, thewater absorbent resin particles or the water absorbing agent (0.900 g)evenly contained in a container was swollen in a synthesized urine(Jayco synthesized urine of the patent) under a pressure of 0.3 psi(2.07 kPa) for 60 minutes, and a height of a gel layer was recorded.Then, 0.69 mass % physiological saline was made to flow from a tank andto pass through the swollen gel layer at a constant hydrostaticpressure. The SFC test was carried out at a room temperature (20° C. orhigher and 25° C. or lower).

Production Example 1 in which Water Absorbent Resin Powder is Produced

The water absorbent resin powder was continuously provided by using acontinuous production apparatus (which allows production of 500 kg ofthe water absorbent resin powder per an hour) which links thepolymerization step (still polymerization on a belt), the gelgranulation step, the drying step, the pulverization step, theclassification step, the surface treatment step (the cross-linking agentspraying step, the heating step, the cooling step), the classificationstep, and the metallic foreign substance removal step (see U.S. Pat. No.6,716,894, Patent Document 6) and can continuously carry out therespective steps.

That is, first, an acrylic acid partial sodium chloride aqueous solution(concentration: 38 mass %) which contained 0.06 mol (with respect to amonomer) of polyethyleneglycol diacrylate (average n number: 9) servingas an internal cross-linking agent and whose 75 mol % was neutralizedwas used as a monomer aqueous solution (1), and the resultant monomeraqueous solution (1) was continuously fed by a constant pump, andnitrogen gas was continuously imbued into a pipe, thereby setting oxygenconcentration to 0.5 ppm or less.

Next, 0.14 g/monomer mol of sodium persulfate and 0.005 g/monomer mol ofL-ascorbic acid were further mixed with the monomer aqueous solution (1)by line mixing, and was supplied to a flat steal belt with a side guardso that the mixture had the thickness of about 25 mm, so as tocontinuously carry out aqueous solution polymerization for 30 minutes.The hydrogel cross-linked polymer (i) obtained in this manner wascrushed and then was fragmented into pieces each having a diameter ofabout 1 mm by a meat chopper whose diameter was 7 mm. These pieces werespread on a perforated plate of a band dryer and were continuously driedby hot air of 180° C. for 30 minutes, thereby obtaining a dried polymer.

The dried polymer was pulverized, and an entire amount of the resultantparticulate dried polymer was continuously supplied to a triple rollgranulator (roll gaps are 1.0 mm, 0.55 mm, and 0.42 mm downward) so asto pulverize the particulate dried polymer and then was classified by asieving apparatus having metal sieve gauzes whose mesh sizes were 850 μmand 150 μm, thereby obtaining the water absorbent resin powder (1)containing about 98 mass % of particles whose particle diameter rangesfrom 850 to 150 μm (CRC=35 g/g). Table 1 shows results obtained bymeasuring properties of the water absorbent resin powder (1).

Further, the water absorbent resin powder (1) is continuously suppliedto a high speed continuous mixer (turbulizer/1000 rpm) at 1000 kg/hr,and a surface cross-linking agent aqueous solution including 1.0 mass %of propyleneglycol, 2.5 mass % of water, and 0.5 mass % of aluminumsulfate octadecahydrate (each amount thereof is relative to the waterabsorbent resin powder) was sprayed with each droplet having a diameterof about 250 μm so as to be mixed with the water absorbent resin powder(1).

Subsequently, the resultant mixture was continuously heated at 195° C.for 40 minutes by a paddle dryer, and then was forcibly cooled down to60° C. Further, particles (2) having passed through a metal gauze whosemesh size was 850 μm were classified by using the sieving apparatushaving the metal gauze, and particles (1) having not passed through themetal gauze whose mesh size was 850 μm were pulverized again and weremixed with the particles (2), thereby obtaining water absorbent resinpowder (2) entirely constituted of particles having passed through the850 μm metal gauze (water absorbent resin powder (1) whose surface hadbeen cross-linked by propyleneglycol and aluminum sulfate).

Table 1 shows results obtained by measuring properties of the resultantwater absorbent resin powder (2). Note that, the water absorbent resinpowder (2) was packaged into a non-permeable bag so that each bagcontained 500 Kg of the water absorbent resin powder (2) as a singleLot.

TABLE 1 ABSORB- SALINE FLOW ENCY CONDUCTIVITY ABSORB- AGAINST (SFC) ENCYPRESSURE (×10⁻⁷(cm³ × (g/g) (g/g) s × g⁻¹)) WATER ABSORBENT 35  10≤ 1RESIN POWDER (1) WATER ABSORBENT 30 23 60 RESIN POWDER (2) In each waterabsorbent resin powder, a mass average particle diameter is about 390μm, an extractable polymer content is about 13 mass %, a color is white(YI = about 10), and a solid content is about 99 mass %.

Comparative Example 1

In Production Example 1, 300 g of the water absorbent resin powder wasarbitrarily retrieved from Lot of the water absorbent resin powder (1)and was spread into a single layer whose area size was about 1 m², andthen whether there were any foreign matters or not were checked. Therewas confirmed a ratio of Lots each of which included one or more foreignmatters (black particles) in 300 g of particles (entirely having passedthrough the 850 μm metal gauze) spread into a layer of 1 m². As aresult, the foreign matters were contained in about 9% of the entireLots (9 lots/100 lots).

Example 1

Color particles having passed through the 850 μm metal gauze ofProduction Example 1 were monitored by an image sensor, and a certainamount of powder was retrieved from an automatic damper by detecting thecolor particles, and only the retrieved color particles were sorted. Outof the color particles, only color-sorted particles (1′) having passedthrough the 850 μm metal gauze were subjected to the foregoing stepagain. As in Production Example 1, the particles (1′) were pulverizedand were mixed with the particles (2), thereby obtaining water absorbentresin powder (1A) entirely constituted of particles having passedthrough the 850 μm metal gauze. As a result, the ratio of Lots includingforeign matters in the water absorbent resin powder (1A) was decreasedto 6% (6 lots/100 lots). Note that, a ratio at which the color particleswere removed from the color-sorted particles (1) having passed throughthe 850 μm metal gauze was 66%, and a ratio of the color-sortedparticles having passed through the 850 μm metal gauze was about 50%with respect to an entire amount of the foreign matters.

Example 2

As to the water absorbent resin powder (2) including about 6000 foreignmatters (black foreign substances) per 1000 kg of particles, an entireamount of the particles (a ratio of particles whose particle sizedistribution ranged from 850 to 150 μm was 98%) was subjected to colorsorting, by using a color sorting apparatus “Final Sorter” (product ofSATAKE CORPORATION) having a single side monitoring camera, at athroughput of 470 Kg/h. As a result, an yield was 95.6%, a sortingability was 90%, and 90% of the foreign matters was removed, and theforeign matters were substantially not found by eyes.

Example 3

The same operation as Example 2 was carried out except that thethroughput of the color sorting apparatus was changed to 3500 Kg/h. As aresult, the yield was 98.6%, the sorting ability was 43%, and theforeign matters were hardly found by eyes.

Example 4

The yield of the water absorbent resin powder having been color-sorted(first sorting) in Example 2 was 95.6%, and 4.4% of the water absorbentresin powder including foreign matters was further color-sorted (secondsorting). As a result, the yield increased to 99.9%.

Production Example 2 in which Water Absorbent Resin Powder is Produced

On the basis of Example 8 of U.S. Patent Publication No. 2007-041796,continuous belt polymerization was carried out, thereby obtaining waterabsorbent resin powder whose surface had been cross-linked by aluminumsulfate and which included hexahedral (cubical) particles having anaverage particle diameter of 4 mm.

That is, on the basis of Example 8 of U.S. Patent Publication No.2007-041796, a monomer aqueous solution was prepared by sufficientlymixing a monomer including 15.9 kg of acrylic acid and 173.4 kg of 37mass % sodium acrylate aqueous solution, 104.6 g of polyethyleneglycoldiacrylate (n=9), 7.9 kg of ion exchange water, and 2.7 kg of 15 mass %polyethyleneglycol (commercial name: Polyethyleneglycol 6000, producedby NOF CORPORATION) aqueous solution. Then, a solution containing 3% ofhydroxy cyclohexyl phenylketone and sodium persulfate was used as apolymerization initiator, and an endless steel belt was used to carryout continuous belt polymerization while emitting an ultraviolet ray.

A moisture content of a resultant hydrogel was 45.0 mass % and thethickness of the hydrogel was 4.5 mm. The hydrogel contained hexahedralparticles each of which was a cube of about 4 mm×4 mm×4 mm. Note that,in cutting the hydrogel, 19.05 mass % of propyleneglycol was sprayed soas to coat a surface of the hydrogel. Further, 600 g of 10 mass %aluminum sulfate aqueous solution was sprayed to 40 kg of the hydrogel,and then the hydrogel was dried by hot air of 150° C. for 50 minutes soas to carry out the drying at the same time as the surfacecross-linking. Further, agglomerates were sorted.

A moisture content of resultant water absorbent resin powder (3) was12%. A mass average particle diameter was 4.0 mm, and an amount of finepowder whose particle diameter was 150 μm or less was 0%, and alogarithmic standard deviation σζ was 0.18 (for detail information, seeU.S. Patent Publication No. 2007-041796).

Comparative Example 2

Continuous production including the continuous belt polymerization wascarried out by linking the respective steps of Production Example 2, sothat no foreign matters were initially found. However, afterseveral-month operation, four black foreign matters were found in 10 kgof the water absorbent resin powder on average at the time of temporarystoppage of the operation.

Example 5

The same operation as Comparative Example 2 except that the waterabsorbent resin was supplied to Kubota powdery foreign substance sorter“PLATON” (product of Kubota Corporation) at 150 kg/h right beforepackaging a final product and at a final step of the continuousproduction and was color-sorted. As a result, the yield was 99.5%, and100% of the foreign matters were removed from the water absorbent resinwhose yield was 99.5%.

Example 6

The yield of the water absorbent resin powder having been color-sorted(first sorting) in Example 5 was 99.5%, and 0.5% of the water absorbentresin powder including foreign matters was further color-sorted (secondsorting). As a result, the yield increased to 99.99% and 100% of theforeign matters were removed.

Note that, when the foreign matters were removed in Examples 1 to 6,there was no change or there was slight improvement in properties byseveral points before and after the color sorting.

Production Example 3 in which Water Absorbent Resin Powder is Produced

On the basis of Example 1 of U.S. Pat. No. 6,867,269, continuous kneaderpolymerization was carried out, thereby obtaining water absorbent resinpowder (4).

That is, a mixture solution (concentration was 45% and temperature was97° C.) was prepared by mixing 493.2 g of acrylic acid, 396.1 g ofaqueous solution containing 48 mass % of sodium hydroxide, 419.6 g ofwater, 6.0 g of aqueous solution containing 0.5 mass % ofdiethylenetriamine pentaacetate and pentasodium, 1.0 g ofpolyethyleneglycoldiacrylate (average polyethyleneglycol unit number: 8)serving as an internal cross-linking agent, and 11.3 g of aqueoussolution containing 3 mass % of sodium persulfate, in a line mixingmanner, and the mixture solution was continuously supplied to acontinuous kneader (CKDJS-40 produced by DALTON CO., LTD) serving as apolymerization container having a biaxial stirring vane so that theforegoing amounts were supplied per minute. The hydrogel cross-linkedpolymer was sheared and the crushed hydrogel (4) was continuouslydischarged from the polymerization container.

The resultant hydrogel (4) was dried with hot air of 170° C. for 40minutes and was further pulverized and classified, thereby obtainingabout 36 kg of water absorbent resin powder (4) (GVs=39 g/g, solublecontent was 12%) per hour (for detail information, see U.S. Pat. No.6,867,269).

Production Example 4 in which Water Absorbent Resin Powder is Produced

As in Production Example 1, the water absorbent resin powder wassubjected to surface cross-linking, thereby obtaining water absorbentresin powder (5).

Comparative Example 3

As to the water absorbent resin powder (5) continuously obtained throughProduction Example 3 and Production Example 4, when continuousproduction thereof was continued, about 4000 foreign matters occurred in1000 kg of particles.

Example 7

After a final step of the continuous production steps, the waterabsorbent resin powder (5) continuously obtained through ProductionExample 3 and Production Example 4 was continuously subjected to thefirst and second sorting in line by using Kubota powdery foreignsubstance sorter “PLATON” (product of Kubota Corporation). As a result,the yield was 99.8%. Further, 97% of the foreign matters were removed.

Example 8

As to the water absorbent resin powder obtained by carrying out thefirst and second sorting in Example 7, properties thereof were measured.As a result, even after producing 100 ton of the water absorbent resinpowder, (a) PUPP was 65%, (b) an amount of contained foreign matters was0 mm²/100 g, (c) an amount of fine powder whose particle diameter was150 μm or less was 1 mass %, D50=380 μm, σζ=0.33, AAP was 23 g/g, aresidual monomer was 300 ppm, and a solid content was about 99 mass %.

Example 9

On the basis of WO2006-109844, 50 wt % of water absorbent resin powderand 50 wt % of pulp were dry blended, thereby producing a core whosediameter was 9 cm and basic weight was 2 g/cm².

As to the core (an absorption layer model of a diaper), substantially noforeign matters were found in the water absorbent resin powder obtainedin Examples 1 to 4 and Example 7. While, in the water absorbent resinpowder of Comparative Examples 1 and 3, foreign matters in the pulp wererelatively easily confirmed.

On the basis of WO2006-109844, a re-wet of the water absorbent resinpowder obtained in Example 8 was measured with 25 ml of physiologicalsaline and at a load of 4.9 kPa. As a result, the re-wet was 5 g. Thisis a favorable value.

As described above, a method according to the present invention forproducing water absorbent resin powder whose mass average particlediameter defined by sieve classification is 300 μm or more and 10 mm orless and which contains less than 10% by mass of fine powder having aparticle diameter of 150 μm or less and has a surface cross-linkedstructure, said method being characterized by comprising: apolymerization step in which an unsaturated monomer aqueous solution ispolymerized; a drying step in which a hydrogel cross-linked polymerobtained in the polymerization step is dried; a surface treatment stepin which the hydrogel cross-linked polymer or a dried hydrogelcross-linked polymer is subjected to a surface treatment; and a sortingstep, carried out after the drying step, in which a foreign matterincluded in a water absorbent resin is color-sorted from the waterabsorbent resin entirely or partially.

Thus, as to high-property-water absorbent resin powder in which foreignmatters are likely to occur, it is possible to improve a productionefficiency and it is possible to efficiently provide a water absorbentresin which is free from uncomfortable appearance, has excellentwhiteness, and is less likely to be colored.

The invention being thus described, it will be obvious that the same waymay be varied in many ways. Such variations are not to be regarded as adeparture from the spirit and scope of the invention, and all suchmodifications as would be obvious to one skilled in the art are intendedto be included within the scope of the following claims.

INDUSTRIAL APPLICABILITY

As described above, the present invention includes as a production stepa sorting step adopting a color sorting technique, so that it ispossible to efficiently remove black or brown foreign matters which arelikely to occur in continuously producing a water absorbent resin havingparticularly high properties. Thus, the present invention is widelyapplicable to fields concerning production of sanitary materials such asdiapers required to have high properties and excellent whiteness.

The invention claimed is:
 1. A package of water absorbent resin powderobtained by carrying out cross-linking polymerization with respect to anunsaturated monomer containing acrylic acid and/or salt thereof as amain component, said package comprising a non-permeable bag or anon-permeable container containing 20 kg to 200000 kg of the waterabsorbent resin powder as each package, a production volume of thepackage being 100 Mton or more, said water absorbent resin powdersatisfying the following properties: (a) an amount of a foreign matterincluded in the water absorbent resin powder and being a nonmagnetic andblack or brown organic substance is 5 mm²/100 g or less; (b) anabsorbency against pressure (AAP: 0.90 g) is 20 g/g or more and 60 g/gor less; (c) an amount of fine powder whose particle diameter is 150 μmor less is 0 mass % or more and 5 mass % or less, and a mass averageparticle diameter (D50) is 200 μm or more and 550 μm or less, and aparticle size distribution logarithmic standard deviation (σζ) is 0.20or more and 0.40 or less, defined by standard sieve classification.